Power supply device, power supply housing for power supply device, and manufacturing method of power supply device

Abstract

The power supply device includes multiple battery modules formed by connecting multiple rechargeable battery cells, and a power supply housing. The power supply housing includes: a housing body having a first surface and a second surface opposite the first surface, the first surface having multiple insertion ports for storing the multiple battery modules in a pluggable state; and a plate portion fixed to a portion of the housing body, composed of components different from the housing body. The plate portion has a stop portion that, when multiple battery modules are inserted from their respective end faces through the insertion ports of the housing body towards the second surface, interferes with the end faces of the battery modules to limit the amount of insertion.

Description

Technical Field

[0001] This disclosure relates to a power supply device, a power supply housing for a power supply device, and a method for manufacturing a power supply device. Background Technology

[0002] Battery modules, which are composed of multiple rechargeable secondary battery cells such as lithium-ion batteries connected in series and parallel, are used as power supply devices to drive the objects they power. For example, backup power supply devices are used where multiple battery modules, which are composed of multiple secondary battery cells connected in series and parallel, are inserted into a rack.

[0003] The backup power supply for data centers consists of multiple battery modules, electrical components, and a power supply housing. Each battery module is designed for plugging and unplugging. Additionally, the power supply unit includes internal stops to prevent interference between the battery modules and electrical components during insertion and removal.

[0004] Such a stop is used to position the battery module when it is inserted into the rack. Specifically, when the battery module is pressed into the designated position, the stop abuts against the end face of the battery module to prevent further pressing. Thus, the battery module is held in a fixed position. Furthermore, in this state, a housing-side connector mounted on the circuit board located on the inside of the power supply housing is fitted with a battery-side connector provided on the end face of the battery module, electrically connecting the battery module to the circuit board of the power supply housing.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: US Patent Application Specification US2019 / 0273366A

[0008] Patent Document 2: US Patent Application Specification US2018 / 0063988A Summary of the Invention

[0009] High capacity and high output of battery modules constituting the power supply device are required. However, if the battery module is to be lengthened to include more secondary battery cells, the power supply housing needs to be redesigned by changing the position of the stop accordingly. In particular, the position of the stop, which determines the insertion allowance of the battery module, varies depending on the length of the battery module, thus making it impossible to generalize the design of the power supply housing for battery modules with different lengths in the longitudinal direction.

[0010] One objective of this disclosure is to provide a power supply device that can accommodate variations in the length of the battery module. Another objective is to provide a power supply device that allows for a universal power housing even when the battery module length varies. Furthermore, the description of these objectives and objectives does not preclude the existence of other objectives and objectives. Moreover, one solution of this disclosure does not need to solve all of these objectives. Furthermore, objectives beyond these can be extracted from the description, drawings, and claims of this disclosure.

[0011] One aspect of the power supply device disclosed herein includes multiple battery modules, each having multiple secondary battery cells, and a power housing for housing the multiple battery modules. The power housing includes: a housing body having a first surface and a second surface opposite to the first surface, the first surface having multiple insertion ports for housing the multiple battery modules in a pluggable state; and a plate portion fixed to a portion of the housing body, composed of components different from the housing body. The plate portion has a stop portion that, when the multiple battery modules are inserted from their respective end faces into the insertion ports of the housing body towards the second surface, interferes with the end faces of the multiple battery modules to limit the amount of insertion.

[0012] Another aspect of the power supply housing disclosed herein is a power supply housing for a power device used to house multiple battery modules formed by connecting multiple secondary battery cells. This power supply housing comprises: a housing body having a first surface and a second surface opposite to the first surface, the first surface having multiple insertion ports for housing the multiple battery modules in a pluggable state; and a plate portion fixed to a portion of the housing body, composed of components different from the housing body. The plate portion has a stop portion that, when the multiple battery modules are inserted from their respective end faces through the insertion ports of the housing body toward the second surface, interferes with the end faces of the battery modules to limit the amount of insertion.

[0013] Furthermore, one aspect of the power supply device manufacturing method disclosed herein includes a power supply device comprising multiple battery modules, each having multiple secondary battery cells, and a power supply housing for housing the multiple battery modules. The power supply housing comprises: a housing body having a first surface and a second surface opposite to the first surface, the first surface having multiple insertion ports for housing the multiple battery modules in a pluggable state; and a plate portion fixed to a portion of the housing body, composed of components different from the housing body. The manufacturing method includes: preparing the plate portion having a stop portion, wherein the stop portion, when the multiple battery modules are inserted from their respective end faces into the insertion ports of the housing body toward the second surface, interferes with the end faces of the battery modules to limit the amount of insertion; and fixing the plate portion to a portion of the housing body.

[0014] According to one aspect of the present disclosure, the power supply device, the power supply housing for the power supply device, and the manufacturing method of the power supply device are such that by making the plate portion with the stop portion composed of a different component from the housing body, even if the length of the inserted battery module changes, it can be handled by simply replacing the plate portion whose position of the stop portion has been changed accordingly, thus avoiding the need to redesign the housing body. Attached Figure Description

[0015] [ Figure 1 ] Figure 1 This is an exploded perspective view showing the state of plugging and unplugging a battery module relative to the power supply device in Embodiment 1.

[0016] [ Figure 2 ] Figure 2 Viewed from the back side Figure 1 The exploded three-dimensional diagram obtained from the power supply device.

[0017] [ Figure 3 ] Figure 3 yes Figure 1 An exploded perspective view of the power supply housing of the power supply device.

[0018] [ Figure 4 ] Figure 4 Viewed from the back side Figure 3 An exploded three-dimensional view obtained from the power supply casing.

[0019] [ Figure 5 ] Figure 5 From Figure 4 An exploded perspective view of the power supply housing with the circuit board and insulating sheet removed.

[0020] [ Figure 6 ] Figure 6 yes Figure 5An enlarged 3D view of the power supply casing.

[0021] [ Figure 7 ] Figure 7 From Figure 5 An exploded perspective view of the power supply housing with the board removed.

[0022] [ Figure 8 ] Figure 8 yes Figure 1 A vertical sectional view of the power supply unit at line VIII-VIII.

[0023] [ Figure 9 ] Figure 9 yes Figure 1 An exploded 3D view of the battery module.

[0024] [ Figure 10 ] Figure 10 This is a schematic cross-sectional view of the power supply device according to Embodiment 1.

[0025] [ Figure 11 ] Figure 11 It means to Figure 10 A schematic cross-sectional view showing the housing body with battery modules of different lengths inserted.

[0026] [ Figure 12 ] Figure 12 This is an exploded perspective view of the power supply device of the comparative example, viewed from the rear side.

[0027] [ Figure 13 ] Figure 13 This is an enlarged perspective view of the stop part of the power supply device in the comparative example.

[0028] [ Figure 14 ] Figure 14 This is a schematic cross-sectional view showing the insertion of a battery module into the power supply housing in the power supply device of the comparative example.

[0029] [ Figure 15 ] Figure 15 It means in Figure 14 A schematic cross-sectional view of the battery module in the power supply device in an elongated state.

[0030] [ Figure 16 ] Figure 16 This is a schematic cross-sectional view of a power supply device representing a modified example.

[0031] [ Figure 17 ] Figure 17 This is a three-dimensional view of the plate.

[0032] [ Figure 18 ] Figure 18 This is a perspective view of the plate portion of the power supply device according to Embodiment 2.

[0033] [ Figure 19 ] Figure 19 This is a perspective view of the plate portion of the power supply device according to Embodiment 3. Detailed Implementation

[0034] The manner of this disclosure can also be determined through the following structure and features.

[0035] In another aspect of the power supply device disclosed herein, in the above-described manner, the housing body has a plurality of storage spaces formed inside, the plurality of storage spaces being respectively connected to the plurality of plug-in ports and respectively storing the plurality of battery modules.

[0036] Furthermore, for another aspect of the power supply device disclosed herein, in any of the aforementioned aspects, the end face of the plate portion is not exposed upwards from the bottom surface of each storage space. According to the above structure, interference from the end face of the plate portion that would hinder insertion of the battery module into the power supply housing can be avoided.

[0037] Furthermore, regarding another aspect of the power supply device disclosed herein, in any of the aforementioned aspects, the mounting surface of the housing body on which the plurality of battery modules are mounted and the upper surface of the plate portion are formed as a single plane on the inner surface of the housing body. According to this structure, although the plate portion is attached to the housing body, no change in the height direction is caused by the addition of the plate portion, thus avoiding interference with the plate portion when the battery modules are pressed in.

[0038] Furthermore, for a power supply device according to another aspect of this disclosure, in any of the above aspects, the housing body is formed with a bottom opening that partially opens its bottom surface, and the plate portion is configured to close the bottom opening.

[0039] Furthermore, in another aspect of the power supply device disclosed herein, in any of the above aspects, a circuit board is further included, disposed inside the housing body between the end faces of the plurality of battery modules and the second face, and the plate portion is provided with a plate-side plate fixing portion for partially fixing the circuit board. According to the above structure, when the width of the circuit board changes accordingly to the change in the length of the battery modules inserted into the power supply housing, the position of the plate-side plate fixing portion provided in the plate portion can be adjusted according to the changed width of the circuit board, thus accommodating circuit boards of different depths without requiring a redesign of the housing body.

[0040] Furthermore, in another aspect of the power supply device disclosed herein, in any of the above-described embodiments, the housing body is provided with a housing-side substrate fixing portion for fixing another portion of the circuit board. According to the above structure, while fixing the position of the housing-side substrate fixing portion provided on the housing body, the position of the board-side substrate fixing portion provided on the board portion can be varied by changing the board portion, thereby fixing circuit boards of different widths.

[0041] Furthermore, in another aspect of the power supply device disclosed herein, in any of the above aspects, the circuit board is placed within the housing body in an orientation aligned with the insertion direction of the battery module. According to the above structure, the circuit board can be held horizontally between the battery module and the second surface of the housing body.

[0042] Furthermore, in another embodiment of the power supply device disclosed herein, in any of the above embodiments, the housing body has the plurality of insertion / removal ports arranged laterally on the first surface. According to the above structure, a plurality of battery modules can be inserted into and removed from the power supply housing in a laterally arranged configuration.

[0043] Furthermore, for another aspect of the power supply device disclosed herein, in any of the above aspects, the stop portion is formed as a semi-circle when viewed in cross-section.

[0044] Furthermore, regarding another aspect of the power supply device disclosed herein, in any of the aforementioned aspects, the power supply device is a backup power supply for a data center. According to the above structure, particularly in backup power supply devices for data centers, since the dimensions of battery modules, etc., are already specified in the specifications, in order to increase the battery module size and achieve higher capacity, the only option is to extend it in the depth direction. However, if the module length is changed in the depth direction, the power housing itself, including the stop portion, must be redesigned. To address this problem, by providing the stop portion in the plate portion of an independent component, the issue can be resolved while maintaining the commonality of the housing body.

[0045] Furthermore, regarding the manufacturing method of the power supply device according to another aspect of this disclosure, in any of the above aspects, the process of preparing the plate portion includes the following steps: when setting the envisioned maximum value of the battery module length as Lmax and the envisioned minimum value of the battery module length as Lmin, the plate length D1 in the depth direction of the plate portion is determined to be D1 > Lmax - Lmin. Therefore, the position of the stop portion can be changed within the range of the plate length of the plate portion, thereby enabling it to accommodate the entire range of the envisioned battery module length.

[0046] The embodiments of this disclosure will now be described based on the accompanying drawings. However, the embodiments shown below are merely illustrative examples to concretize the technical concept of this disclosure, and this disclosure is not limited to the following content. Furthermore, this specification does not intend to define the components shown in the claims as components of the embodiments. In particular, unless specifically stated, the dimensions, materials, shapes, and relative arrangements of the constituent components described in the embodiments are not intended to limit the scope of this disclosure, but are merely illustrative examples. Moreover, there are instances where the size and positional relationships of the components shown in the drawings are exaggerated for clarity. Furthermore, in the following description, the same names and reference numerals refer to the same or homogeneous components, and detailed descriptions are appropriately omitted. Furthermore, the elements constituting this disclosure may be configured such that one component constitutes multiple elements, or conversely, multiple components may share the function of one component.

[0047] The power supply device disclosed herein can be used in various applications, including fixed power supply devices, backup power supplies for data centers, energy storage devices for storing electricity obtained through solar power generation in homes, businesses, and factories, and power supplies for daytime peak shaving. Hereinafter, as one embodiment of this disclosure, a power supply device used as a backup power supply for a data center will be described. The power supply device for the data center is inserted into a storage space such as a rack, just like hardware such as servers, storage devices, and network switches. Such a rack-mounted power supply device is also referred to as a power rack, etc.

[0048] [Implementation Method 1]

[0049] The power supply device 100 of Embodiment 1 of this disclosure is shown in Figures 1 to 11 In these figures, Figure 1 An exploded perspective view is shown, illustrating the state in which a battery module 2 is plugged in and unplugged relative to the power supply device 100 of Embodiment 1. Figure 2 Shown from the rear side view Figure 1 The exploded three-dimensional view obtained from the power supply device 100. Figure 3 It shows Figure 1 An exploded perspective view of the power supply housing 10 of the power supply device 100. Figure 4 Shown from the rear side view Figure 3 An exploded perspective view of the power supply housing 10. Figure 5 It shows from Figure 4 An exploded perspective view of the power supply housing 10 with the circuit board 30 and insulating sheet 34 removed. Figure 6 It shows Figure 5 An enlarged perspective view of the power supply housing 10. Figure 7 It shows from Figure 5An exploded perspective view of the power supply housing 10 with the board 20 removed. Figure 8 It shows Figure 1 A vertical sectional view of the power supply unit 100 at line VIII-VIII. Figure 9 It shows Figure 1 Exploded perspective view of battery module 2 Figure 10 A schematic cross-sectional view of the power supply device 100 according to Embodiment 1 is shown. Figure 11 It shows the expression to Figure 10 The figures show a schematic cross-sectional view of the power supply unit 100 with battery modules 2' of varying lengths inserted into the main body 11. The power supply unit 100 shown in these figures includes a power supply housing 10 and battery modules 2. Additionally, a circuit board 30 is disposed on the rear side of the power supply housing 10.

[0050] (Power supply housing 10)

[0051] The power supply housing 10 is a component used to house one or more battery modules 2 in a pluggable manner, forming the outer shape of the power supply device 100. The power supply housing 10 is composed of a housing body 11 with a box-shaped exterior, having a first surface 12 and a second surface 13 as its opposite surface. Figure 1 , Figure 2 In the example, the front side of the housing body 11 is designated as the first surface 12, and the back side as the second surface 13. The first surface 12 has insertion / removal ports 14 for inserting and removing the battery module 2. Figure 1 , Figure 2 In the example of the power supply housing 10, the housing body 11 is designed to be flat, and the plug-in ports 14 are arranged horizontally on the first surface 12 on the front side, and multiple battery modules 2 are arranged horizontally.

[0052] Specifically, such as Figures 3-7 As shown in the exploded perspective view, the main body 11 is divided into four parts: a first main body shell 15, a second main body shell 16, a third main body shell 17, and a fourth main body shell 18. The first main body shell 15 and the second main body shell 16 form a cover, which closes the upper surface of the third shell, which is bent in the shape of the Japanese kana character "コ" with an opening on the upper surface. Furthermore, the back side, the second surface 13, of the main body 11 is closed by the fourth main body shell 18. Moreover, inside the main body 11, multiple partition plates 19 are arranged in parallel, separated, and fixed to each other, dividing the space into multiple storage spaces 3. Each storage space 3 is connected to the plug-in port 14 and houses the battery module 2. In addition, in... Figures 3-7In the example shown, due to the illustration, the state in which multiple partition plates 19 are fixed to the bottom surface of the third main housing 17 is illustrated. However, it is self-evident that multiple partition plates 19 can also be fixed to the first main housing 15 in place of the third main housing 17, or in addition to the third main housing 17. Furthermore, the second main housing 16 is separately constructed from the first main housing 15, which facilitates contact with the circuit board 30 and the board portion 20 when the multiple partition plates 19 are fixed to the first main housing 15 and the third main housing 17.

[0053] (Circuit board 30)

[0054] Furthermore, on the rear side of the housing body 11, a circuit board 30 is disposed between the second surface 13 and the battery module 2. The circuit board 30 is mounted inside the housing body 11 in an orientation aligned with the insertion direction of the battery module 2. That is, the circuit board 30 is held horizontally between the battery module 2 and the second surface 13.

[0055] The circuit board 30 is equipped with: a current detection circuit for detecting the charging and discharging current; a circuit for detecting and calculating the full charge and remaining capacity of the secondary battery cells based on battery information such as voltage and temperature of the secondary battery cells input from the battery-side circuit board of the battery block, which has multiple interconnected secondary battery cells; a control circuit for controlling the charging and discharging of the secondary battery cells; and a protection circuit for monitoring whether the battery is functioning properly. The circuit board 30 is formed in a rectangular shape. Figure 4 In examples such as these, the circuit board 30 is fixed horizontally on the back side of the power supply housing 10. Preferably, the circuit board 30 is made of resin such as glass epoxy resin.

[0056] Alternatively, when the circuit board 30 is disposed inside the housing body 11, such as... Figure 5 An insulating sheet 34 is sandwiched in as shown. This improves the insulation of the back side of the circuit board 30.

[0057] Furthermore, the power supply housing is not limited to the above-described manner; it can also be configured such that the plug-in ports are stacked vertically on the main body of the housing in a longitudinal arrangement. Alternatively, the housing portions can be arranged in a checkerboard pattern. Furthermore, it is not necessary to insert housing portions into all the plug-in ports 14 of the power supply housing 10; the number of housing portions inserted into the power supply housing can be set according to the required output, capacity, etc., of the power supply device. Additionally, the shape and length of the opening of the plug-in port are designed according to the size of the battery module being plugged in. Moreover, it is preferable that the main body of the housing 11 is made of metal, such as a metal plate with excellent heat dissipation.

[0058] (Battery Module 2)

[0059] The battery module 2 is inserted and removed relative to the insertion port 14 of the housing body 11. The battery module 2 is shaped as a rod extending in one direction for easy insertion and removal. Preferably, the rod-shaped battery module 2 is box-shaped. The box-shaped battery module 2 has one end face in the length direction DL as an insertion surface 41 for insertion into the housing body 11. The other end face is an exposure surface 42 that protrudes from the housing body 11 when inserted. Figure 1 In examples like these, the battery module is formed into a prism shape with a square end face. However, the shape of the battery module is not limited to this; the end face can also be rectangular, octagonal, or other shapes.

[0060] like Figure 9 As shown, in each battery module 2, multiple secondary battery cells 1 are housed within a box-shaped module housing 43. Each battery module 2 outputs its output to the power supply housing 10 by connecting the multiple secondary battery cells 1 in series and parallel. Therefore, the battery module 2 is provided with a battery-side connector 44 for connecting to the power supply housing 10. In addition, the housing body 11 is provided with a housing-side connector 32 for connecting to the battery-side connector 44.

[0061] The battery-side connector 44 is located on the insertion surface 41 side of the battery module 2. Additionally, the housing-side connector 32 is positioned on the circuit board 30 opposite to the insertion surface 41 of the battery module 2. When the battery module 2 is inserted into the housing body 11, and the insertion surface 41 abuts against the stop portion 21 (described later) and stops, the battery-side connector 44 and the housing-side connector 32 engage. The battery-side connector 44 and the housing-side connector 32 are configured in the manner described above.

[0062] like Figure 9 As shown in the exploded perspective view, the module housing 43 of the battery module 2 is formed into a box shape extending in the front-to-back direction, and has a component storage space for the internal components 45 inside. The module housing 43 is composed of a first module housing 43A, which is shaped like the Japanese kana character "コ" in cross-section and has an open lower surface, and a second module housing 43B, which closes the lower surface of the first module housing 43A. The first module housing 43A and the second module housing 43B are formed into a predetermined shape by bending or other processes on a metal sheet. For example, galvanized steel sheet, aluminum, or aluminum alloy can be used as such a metal sheet.

[0063] Additionally, an internal component 45 is housed within the component storage space inside the module housing 43. The internal component 45 includes a battery block comprising multiple secondary battery cells 1 and an output unit with output terminals. Within the battery block, multiple cylindrical secondary battery cells 1 are arranged vertically and parallel to each other in a battery holder. The battery holder is preferably made of a material with excellent insulation and heat resistance, such as polycarbonate or ABS resin. The multiple secondary battery cells 1 are connected in parallel and in series. The secondary battery cell 1 is a lithium-ion secondary battery. Using lithium-ion secondary batteries as the secondary battery cells in the battery module 2 increases the output relative to volume and weight. However, lithium polymer batteries or nickel-metal hydride batteries can also be used instead of lithium-ion batteries for the secondary battery cells. Therefore, this disclosure does not specify lithium-ion batteries as the secondary battery cells; all rechargeable batteries can be used.

[0064] Furthermore, in the battery pack, the module substrate is vertically positioned on the side of the battery holder, and the lead plate 46, which is connected to the end electrode of the secondary battery cell 1, is connected to the module housing 43 to detect the intermediate potential of the secondary battery cells 1 connected in series. Furthermore, the module housing 43 has an electronic circuit for detecting the state of multiple secondary battery cells 1. This electronic circuit includes a voltage detection circuit for detecting the total potential and intermediate potential of the battery assembly formed by the series and parallel connection of the secondary battery cells 1, and a circuit for detecting the temperature of the multiple secondary battery cells 1.

[0065] (Plate 20)

[0066] In addition, such as Figures 5-7 , Figure 10 As shown, the power housing 10 includes a plate portion 20, which is fixed to a portion of the housing body 11 and is constructed of components different from those of the housing body 11. The plate portion 20 is provided with a stop portion 21. This stop portion 21, when multiple battery modules 2 are inserted from their respective end faces (insertion faces 41) into the housing body 11 through their respective insertion ports 14 toward the second face 13, interferes with, or abuts against, the end faces (insertion faces 41) of the battery modules 2, thereby limiting the amount of insertion. Thus, by making the plate portion 20, which has the stop portion 21, constructed of components different from those of the housing body 11, even if the length of the inserted battery modules 2' exceeds the limit... Figure 10 The L1 was changed to Figure 11 The L2 can also be addressed by preparing a plate 20' that changes the position of the stop 21' accordingly, thus avoiding the need to redesign the housing body 11.

[0067] Here, a comparative example of a data center-oriented power supply unit 600 is shown. Figure 12An exploded perspective view. As shown in the figure, the power supply unit 600 for a data center comprises a power supply housing 610, multiple battery modules 602 that are pluggable and removable relative to the power supply housing 610, and electrical components 630. The battery modules 602 are designed to be removable and replaceable. In this power supply unit 600, a stop is provided in the power supply housing 610 to prevent interference between the battery modules 602 and the electrical components 630 when the battery modules 602 are inserted or removed. The stop is provided for positioning the insertion clearance of the battery modules 602 and is also referred to as a locking element, etc. Figure 13 In the power supply device 700, a pin-shaped stop is used as the stop part 721.

[0068] like Figure 14 As shown in the schematic cross-sectional view, the stop 821 is used to position the battery module 802 when it is inserted into the power housing 810. Specifically, when the battery module 802 is pressed into a predetermined position, the stop 821 abuts against the end face of the battery module 802 to prevent further pressing. Thus, the battery module 802 is held in a fixed position. Furthermore, in this state, the housing-side connector 832 mounted on the circuit board 830 located on the inner side of the power housing 810 engages with the battery-side connector 844 provided on the end face of the battery module 802, electrically connecting the battery module 802 and the circuit board 830 of the power housing 810.

[0069] Such data center-oriented power supply units are inserted into storage spaces such as racks. On the other hand, equipment used in data center applications generally conforms to standards, including hardware such as servers, storage devices, and network switches, which also include power supply units. For example, a power supply unit located in the center of the rack may house six battery modules used for backup purposes. Several specifications exist, and in representative specifications, the height of rack-mounted equipment is defined in units called OU (Open Unit). 1OU is 1.89 inches (48 mm) in height and 21 inches (533.4 mm) in width.

[0070] In recent years, due to the increasing demand for AI generation, there has been a requirement for high-capacity and high-output battery modules 2 that constitute the power supply unit. However, due to size constraints, it is impossible to increase the size of the battery module in the width direction. Therefore, it is necessary to increase the size of the battery module. In this case, in order to enlarge the battery module without changing the size of the rack in which the power supply unit is installed, it is necessary to increase the size of the battery module in the depth direction of the power supply unit, that is, in the length direction in which the battery module is inserted. Therefore, it is necessary to reduce the size of the electrical components on the inner side of the storage space of the rack in which the power supply unit is installed.

[0071] For example, consider the following example: Figure 14 In the power supply device 800 shown, in order to increase the capacity of the battery module 802, as... Figure 15 The power supply device 900 shown will make the overall length ratio... Figure 14 A battery module 902 with a module length L1 and a length of L2 is disposed in the power supply housing 910. The length of the circuit board 930 constituting the electrical section is also correspondingly reduced from B1 to B2. In this case, the length of the battery module 902 is... Figure 14 The battery module 802 is long, therefore the position of the stop 921 used to position the battery module 902 in a fixed position within the power housing 910 needs to be longer than the length of the battery module 902. Figure 14 The stop 821 shifts to the left. As a result, Figure 15 Although the power supply casing of the 910 has a similar shape to Figure 14 The power supply housing 810 is the same, but because the position of the stop inside is different, a new design is required. Thus, the position of the stop, which determines the insertion allowance of the battery module, varies depending on the length of the battery module, making it impossible to universalize the design of the power supply housing for potential modules with different lengths.

[0072] In contrast, in the power supply device 100 of this embodiment, such as Figure 7 As shown in the exploded perspective view, by providing a stop 21 in the plate portion 20, which is composed of components different from the housing body 11, even if the length of the battery module 2 inserted into the housing body 11 changes from L1 to L2, as long as the plate portion 20 with the changed position of the stop 21 is replaced accordingly, it is possible to cope with the situation without redesigning the housing body 11. This allows the housing body 11 to be universal for various types of battery modules 2, thereby reducing manufacturing costs.

[0073] Especially in backup power supply units for data centers, since the diameter of battery modules and the like is already specified in the specifications, in order to increase the battery module size and achieve high capacity, it can only be extended in the depth direction. However, if the module length is changed in the depth direction, the power housing itself, including the stop part, must be redesigned. To address the above problem, by providing the stop part 21 in the plate part 20 of the independent component, it is possible to deal with the problem while making the housing body 11 universal.

[0074] The position of the stop 21 is determined based on the module length of the battery module 2. For example... Figure 10 As shown, based on the module length L1 of the battery module 2, a stop 21 is provided at a position L1 from the first surface 12 of the housing body 11. On the other hand, as... Figure 11As shown, when the battery module 2' has a module length L2, the stop 21' is provided in the plate portion 20' at a position L2 from the first surface 12. Thus, the plate length D1 in the depth direction of the plate portion 20, i.e., the length direction DL in which the battery module 2 is inserted, is designed according to the envisioned module length of the battery module 2, so that the position of the stop 21 can be adjusted according to the module length of the battery module 2. Specifically, it is preferable to design the plate length such that D1 > (maximum value of the envisioned module length Lmax) - (minimum value of the envisioned module length Lmin).

[0075] Additionally, the board portion 20 is provided with a board-side substrate fixing portion 22 for partially fixing the circuit board 30. By providing such a structure, it is possible to achieve... Figure 11 When the width of the circuit board 30' in the depth direction, i.e. the board length, changes according to the change in the length of the battery module 2' inserted into the housing body 11, the position of the board side board fixing part 22' provided on the board part 20' can also be adjusted according to the changed board length of the circuit board 30', so that different board lengths of circuit board 30 can be accommodated without redesigning the housing body 11.

[0076] On the other hand, the housing body 11 is provided with a housing-side substrate fixing part 36 for further fixing the circuit board 30. The circuit board 30 is fixed to the housing body 11 and the board portion 20 by means of the housing-side substrate fixing part 36 and the board-side substrate fixing part 22. Figure 6 , Figure 7 In the example, the aforementioned housing-side substrate fixing part 36 and plate-side substrate fixing part 22 are each composed of cylindrical spacers with threaded grooves cut out on their inner surfaces. However, the housing-side substrate fixing part 36 and plate-side substrate fixing part 22 are not limited to this, and known structures capable of fixing the circuit board 30 can be appropriately utilized.

[0077] Furthermore, the fixing position of the housing-side substrate fixing part 36 is fixed near the second surface 13 side of the housing body 11, while the board-side substrate fixing part 22 is determined according to the substrate length of the circuit board 30. That is, there are cases where the substrate length changes according to the module length, as described above. Therefore, in order to avoid redesigning the housing body 11 due to changes in the substrate length of the circuit board 30, the board-side substrate fixing part 22 of the board part 20 is adjusted. Specifically, in Figure 10 In the example, the position of the board-side substrate fixing part 22 on the board portion 20 is designed such that it is provided at a position approximately B1 from the second surface 13, based on the substrate length B1 of the circuit board 30. Furthermore, in Figure 11In the example, the position of the board-side board fixing part 22' in the board portion 20' is designed such that the board length B2 of the circuit board 30', which is shortened accordingly to the module length L2, is arranged at a position approximately B2 from the second surface 13. With this arrangement, it is possible to accommodate changes in the board length by changing the design of the board portion 20, which helps to make the housing body 11 more versatile.

[0078] The plate portion 20 is fixed to the bottom surface 3B of each storage space 3 in a manner that prevents the end face 120E of the plate portion 20 from protruding upwards from the bottom surface 3B. In other words, when viewed along the length direction DL, the plate portion 20 does not protrude upwards from the bottom surface 3B of the storage space 3. When viewed along the length direction DL, the end face 120E of the plate portion 20 does not protrude upwards from the bottom surface 3B of each storage space 3. By adopting such a structure, it is possible to avoid the situation where the end face 120E of the plate portion 20 gets stuck and hinders insertion when the battery module 2 is inserted into the power housing 10.

[0079] Specifically, the plate portion 20 is fixed at a position connected to the bottom surface 3B of each storage space 3. That is, the mounting surface of the storage space 3, which is divided on the inner surface of the housing body 11, where the battery module 2 is placed, and the upper surface 120A of the plate portion 20 are formed as the same plane.

[0080] exist Figure 7 In the example, a bottom opening 24 is partially provided on the bottom surface of the housing body 11. The plate portion 20 is configured to close the bottom opening 24. Therefore, although the plate portion 20 is attached to the housing body 11, there is no change in the height direction caused by the addition of the plate portion 20, and interference with the plate portion 20 can be avoided when the battery module 2 is pressed in.

[0081] [Variation Example]

[0082] Thus, the structure for attaching the plate portion 20 to the housing body 11 and aligning the bottom surface 3B of the storage space 3 and the upper surface 120A of the plate portion 20 in a coplanar manner is not limited to the method of opening the bottom surface opening 24. As an example, in Figure 16 In the modified power supply device 100' shown in the schematic cross-sectional view, a recess 24' is formed in a portion of the bottom surface of the housing body 11, where the portion for fixing the plate 20 is partially recessed. Even with this structure, the upper surface 120A of the plate 20 can be aligned with the bottom surface 3B of the storage space 3, and the protrusion of the end face 120E of the plate 20 can be avoided. Furthermore, with this structure, compared to a structure with an opening in the housing body 11, the absence of an opening and the partial double-layering of the housing body 11 also provides the advantage of increased rigidity of the housing body 11.

[0083] like Figure 1 , Figure 3 As shown, the housing body 11 has a plurality of insertion ports 14 arranged laterally on its first surface 12. Additionally, as... Figures 5-7 As shown, the plate portion 20 extends in a direction intersecting with the storage spaces 3 in a manner that traverses the multiple storage spaces 3. As a result, the amount of insertion of the end faces, i.e., the insertion surfaces 41, of the multiple battery modules 2 can be limited using a single plate portion 20.

[0084] In addition, such as Figure 7 , Figure 17 As shown, a locking piece 26 can be provided at the end edge of the plate portion 20 to partially engage with the end edge of the housing body 11. This allows for easy alignment of the bottom surface 3B of the storage space 3 and the upper surface 120A of the plate portion 20 in a plane. Furthermore, it is preferable that the locking piece 26 is made thinner or its position adjusted so as not to obstruct the insertion of the battery module 2.

[0085] (Station section 21)

[0086] The plates 20 and 20' are provided with multiple stop portions 21 and 21'. For example... Figure 10 , Figure 11 As shown, for each of the stop portions 21 and 21', when the battery modules 2 and 2' are inserted from the insertion port 14 of the housing body 11 toward the second surface 13, they limit the amount of insertion by interfering with the insertion surface 41 of the battery modules 2 and 2'. Therefore, the stop portions 21 and 21' are respectively provided at positions corresponding to each storage space 3. Figure 10 In the example, a stop 21 is provided for each storage space 3, but it is not limited to this structure. For example, multiple stops can be provided for each storage space.

[0087] The stop 21 only needs to interfere with the insertion surface 41 of the battery module 2 to constrain the battery module 2 from being pressed inwards from a position greater than the stop 21; therefore, its shape can be set to any shape that easily causes interference. Figure 17 In the example shown in the perspective view, the stop portion 21 is formed in an arch shape. Here, the arched stop portion 21 appears as a semi-circle when viewed in cross-section. Such a stop portion 21 has the advantage that it can be easily formed by punching when forming the plate portion 20 from a metal sheet.

[0088] [Implementation Method 2]

[0089] In addition, Figure 18In the power supply device of Embodiment 2 shown, the stop portion 21B provided on the plate portion 20B is formed as a cover-shaped opening on one side. This stop portion 21B uses the open side of the cover-shaped opening to interfere with, or abut against, the insertion surface 41, which is the end face of the battery module 2. Such a stop portion 21B can also be easily formed by stamping a metal sheet. Furthermore, Figure 18 The stop portion 21B needs to have its cover-shaped opening surface facing away from the insertion surface 41 of the battery module 2. This is because if the stop portion 21B faces the opposite direction, there is a possibility that the battery module 2 cannot be restricted from being pressed in due to the inclined surface of the cover.

[0090] [Implementation Method 3]

[0091] Furthermore, in Figure 19 In the power supply device of Embodiment 3 shown, the stop portion 21C provided on the plate portion 20C is formed by cutting a slit in the metal plate portion 20 in the shape of the Japanese kana character "コ" and then pulling it up. This structure of the stop portion 21 also has the advantage of being easy to form. Preferably, Figure 19 The stop portion 21C is also formed with a cut facing the battery module 2 side. This is because, in the opposite orientation, there is a concern that the pulled-up stop portion 21 might tip over due to the pressure of the battery module 2. Alternatively, it could be from... Figure 19 The stop portion 21C is formed by rotating each stop portion 21C 90° in any direction. As a result, the end edge of the stop portion 21C can interfere with the insertion surface 41 of the battery module 2, and the concern that the stop portion 21C will bend in the direction of tilting due to being pressed in can be avoided.

[0092] Furthermore, in the examples above, an example of forming the plate portion 20 from a metal sheet was described. Metal sheets have high strength and are easy to process, making them preferable. On the other hand, as... Figure 7 As shown, it is necessary to consider the insulation of the circuit board 30 fixed to the upper surface 120A of the board portion 20, and measures such as adding an insulating sheet 34 are required.

[0093] [Manufacturing method of power supply device]

[0094] The following describes a method for manufacturing such a power supply device. Here, the power supply device 100 includes multiple battery modules 2 and a power supply housing 10. Multiple secondary battery cells are connected to each of the multiple battery modules 2. The power supply housing 10 includes a housing body 11 and a plate portion 20. The housing body 11 has a first surface 12 and a second surface 13 opposite to the first surface 12. The first surface 12 has multiple insertion ports 14 for storing the multiple battery modules 2 in a pluggable state. The plate portion 20 is fixed to a portion of the housing body 11 and is composed of components different from the housing body 11.

[0095] First, a plate portion 20 with a stop portion 21 is prepared. This stop portion 21 limits the insertion amount by interfering with the insertion surface 41 of the battery module 2 when multiple battery modules 2 are inserted from the insertion face 41 (which serves as each end face) into the second face 13 of the housing body 11. Next, the plate portion 20 is fixed to a portion of the housing body 11. Thus, by using a different component than the housing body 11 for the plate portion 20 with the stop portion 21, even if the length of the inserted battery module 2 changes, it can be handled by simply replacing the plate portion 20, which has a correspondingly changed position of the stop portion 21, thus avoiding the need to redesign the housing body 11.

[0096] The process of preparing the board portion 20 can include the following steps: when setting the maximum value of the envisioned module length of the battery module 2 as Lmax and the minimum value of the envisioned module length of the battery module as Lmin, the board length D1 in the depth direction of the board portion 20 is determined to be D1 > Lmax - Lmin. Therefore, the position of the stop portion 21 can be changed within the range of the board length of the board portion 20, thereby accommodating the entire range of the envisioned module length of the battery module 2.

[0097] Industrial availability

[0098] The power supply device, power supply housing for the power supply device, and manufacturing method of the power supply device disclosed herein can be appropriately used for stationary energy storage devices, such as power supply devices for home, commercial, and factory use, or backup power supplies for data centers.

[0099] Explanation of reference numerals in the attached figures

[0100] 100, 100', Power supply unit; 1. Secondary battery cell; 2. Battery module; 3. Storage space; 10. Power supply housing; 11. Housing body; 12. First side; 13. Second side; 14. Plug-in port; 15. First main housing; 16. Second main housing; 17. Third main housing; 18. Fourth main housing; 19. Divider plate; 20, 20', 20B, 20C, Plate section; 21, 21', 21B, 21C, Stop section; 22, 22', Plate side substrate fixing section; 24. Bottom opening; 24', Recess; 26. Locking piece; 30, 30', Circuit board; 32. Housing side connector; 34. Insulating sheet; 36. Housing side substrate fixing section; 41. 42. Insertion surface; 43. Exposed surface; 44. Module housing; 45. First module housing; 46. Second module housing; 47. Battery-side connector; 48. Internal component; 49. Lead plate; 600. Power supply unit; 602. Battery module; 610. Power supply housing; 630. Electrical component; 721. Stop; 800. Power supply unit; 802. Battery module; 810. Power supply housing; 821. Stop; 832. Housing-side connector; 844. Battery-side connector; 900. Power supply unit; 902. Battery module; 910. Power supply housing; 921. Stop; 930. Circuit board; L1, L2. Module length; B1, B2. Board length; D1. Board length.

Claims

1. A power supply device comprising a plurality of battery modules, each having a plurality of secondary battery cells, and a power housing for housing the plurality of battery modules, wherein, The power supply housing includes: The housing body has a first surface and a second surface opposite to the first surface. The first surface has multiple insertion ports for storing the plurality of battery modules in a pluggable state. The plate portion, which is fixed to a part of the housing body, is composed of components different from those of the housing body. The plate is provided with a stop portion. When the plurality of battery modules are inserted from each end face of the plurality of battery modules toward the second face of the housing body, the stop portion limits the amount of insertion by interfering with each end face of the plurality of battery modules.

2. The power supply device according to claim 1, wherein, The housing body has multiple storage spaces inside, each of which is connected to a plurality of plug-in ports and respectively houses a plurality of battery modules. On the bottom surface of each of the plurality of storage spaces, the end face of the plate portion shall not be exposed upwards from the bottom surface.

3. The power supply device according to claim 1, wherein, On the inner surface of the housing body, the mounting surface of the housing body on which the plurality of battery modules are mounted and the upper surface of the plate portion are formed as the same plane.

4. The power supply device according to claim 1, wherein, The main body of the shell is formed with a bottom opening, which is a partial opening on its bottom surface. The plate portion is configured to close the bottom opening.

5. The power supply device according to claim 1, wherein, The power supply device also includes a circuit board disposed inside the housing body between the end faces of the plurality of battery modules and the second surface. The board portion is provided with a board-side substrate fixing portion for partially fixing the circuit board.

6. The power supply device according to claim 5, wherein, The housing body is provided with a housing side substrate fixing part for fixing another part of the circuit board.

7. The power supply device according to claim 5, wherein, The circuit board is placed inside the housing body in an orientation that follows the insertion direction of the battery module.

8. The power supply device according to any one of claims 1 to 7, wherein, The housing body has the plurality of plug-in ports arranged laterally on the first surface.

9. The power supply device according to any one of claims 1 to 7, wherein, The stop portion is semi-circular when viewed in cross-section.

10. The power supply device according to any one of claims 1 to 7, wherein, The power supply unit is a backup power supply used in data centers.

11. A power supply housing for a power supply device, used to house multiple battery modules, each having multiple individual secondary battery cells, wherein... The power supply housing for the power supply device includes: The housing body has a first surface and a second surface opposite to the first surface. The first surface has multiple insertion ports for storing the plurality of battery modules in a pluggable state. The plate portion, which is fixed to a part of the housing body, is composed of components different from those of the housing body. The plate is provided with a stop portion. When the plurality of battery modules are inserted from the end face of the plurality of battery modules into the second face of the housing body through the insertion port, the stop portion limits the amount of insertion by interfering with the end face of the plurality of battery modules.

12. A method for manufacturing a power supply device, the power supply device comprising multiple battery modules each having multiple secondary battery cells, and a power housing for housing the multiple battery modules, wherein the power housing comprises a housing body and a plate portion, the housing body having a first surface and a second surface opposite to the first surface, the first surface having multiple insertion ports for housing the multiple battery modules in a pluggable state, the plate portion being fixed to a portion of the housing body and composed of components different from the housing body, wherein... The method for manufacturing the power supply device includes: In the process of preparing the plate portion equipped with a stop portion, the stop portion, when inserting the plurality of battery modules from each end face side of the plurality of battery modules into the second face side of the plurality of insertion ports of the housing body, respectively, interferes with each end face of the plurality of battery modules to limit the amount of insertion; and The process of fixing the plate to a portion of the housing body.

13. The method of manufacturing a power supply device according to claim 12, wherein, The process of preparing the plate includes the following steps: When the maximum envisioned length of the plurality of battery modules is set to Lmax and the minimum envisioned length of the plurality of battery modules is set to Lmin, the plate length D1 in the depth direction of the plate portion is determined as follows: D1 > Lmax - Lmin.

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