Battery pack

Abstract

A battery pack fixes an external output terminal exposed from an outer case housing a battery group to an output bus bar. The external output terminal is composed of a press member, and the output bus bar fixes the fixed end of the press member into a connection port in a vertical posture. The outer case has a terminal insertion port through which the press member penetrates at a fixed portion fixing the external output terminal, and a chamfer portion is provided at one of the opening edge portion of the connection port and the opening edge portion of the terminal insertion port, and a ring-shaped rubber-like elastic body is arranged. In a state where the output bus bar is fixed to the fixed portion, the external output terminal is fixed to the outer case in a waterproof structure via the rubber-like elastic body sandwiched between the outer peripheral surface of the press member and the chamfer portion.

Description

Technical Field

[0001] This invention relates to a battery pack in which a plurality of battery cells are built into an outer casing, and particularly to a battery pack in which external output terminals exposed outside the outer casing are configured in a waterproof manner within the outer casing. Background Technology

[0002] Battery packs have been developed that house numerous chargeable and dischargeable battery cells within an external casing. These battery packs are used as power sources for electric vehicles, or for electric heavy equipment, forklifts, and the like. In such power supply devices, solutions exist that expose external charging and discharging terminals from the external casing in order to charge and discharge the built-in battery cells. For example, in battery packs intended for outdoor use, the external output terminals located within the casing are designed to be waterproof and fixed to the casing to prevent rainwater ingress.

[0003] Prior art literature

[0004] Patent documents

[0005] Patent Document 1: JP 2011-103259 Summary of the Invention

[0006] One of the objectives of this invention is to provide a battery pack that can be easily and conveniently fixed to the outer casing with a waterproof construction while reducing manufacturing costs, by means of external output terminals exposed outside the outer casing.

[0007] A battery pack according to a certain aspect of the present invention includes: a battery pack having a plurality of battery cells; an outer casing for housing the battery pack; an external output terminal exposed outside the outer casing; and an output busbar for fixing the external output terminal to a first end and connecting the output terminal of the battery pack to a second end. The external output terminal is composed of a clamping member having a cylindrical shape. The output busbar presses the fixed end of the clamping member into a connection opening at the first end, fixing the clamping member in a vertical position and closing the fixed end side of the clamping member. A portion of the outer casing is designated as a fixing part for fixing the external output terminal, and a terminal insertion port is provided in the fixing part, through which the main body cylindrical portion passes. A chamfer is provided along the opening edge of at least one of the opposing opening edges of the connection opening and the terminal insertion port. Furthermore, an annular rubber-like elastomer through which the clamping member is inserted is disposed at the opening edge of the connection port of the output busbar and at the boundary of the clamping member. The clamping member is inserted into the terminal insertion port. With the output busbar fixed to the fixed part, the opening edge of the connection port, the opening edge of the terminal insertion port and the outer peripheral surface of the clamping member are sealed by the elastically deformable rubber-like elastomer, and the external output terminal is fixed to the outer housing with a waterproof structure.

[0008] The advantage of the battery pack of the present invention is that, without applying special processing to the clamping member, it can fix the output busbar with the clamping member to the outer housing and reliably waterproof it while having a simple structure. Attached Figure Description

[0009] Figure 1 This is a perspective view of a battery pack according to one embodiment of the present invention.

[0010] Figure 2 yes Figure 1 The image shows an exploded perspective view of the battery pack.

[0011] Figure 3 Viewed from below Figure 2 The image shows a 3D view of the back of the battery pack.

[0012] Figure 4 yes Figure 2 An exploded perspective view of the battery pack shown.

[0013] Figure 5 yes Figure 1 Block diagram of the battery pack.

[0014] Figure 6 yes Figure 1 The battery pack shown is a top view.

[0015] Figure 7 yes Figure 6The diagram shows a cross-sectional view of the battery pack cover along line VII-VII.

[0016] Figure 8 yes Figure 6 The diagram shows a cross-sectional view of the battery pack cover along line VIII-VIII.

[0017] Figure 9 yes Figure 7 The exploded cross-sectional view of the cover housing and output busbar shown.

[0018] Figure 10 It is a three-dimensional view of the output busbar with a fixed clamping component.

[0019] Figure 11 This is an enlarged cross-sectional view showing the configuration of the O-rings in the clamping member and the output busbar.

[0020] Figure 12 It is an enlarged cross-sectional view showing the state of waterproofing the clamping component, output busbar and fixed part using O-rings.

[0021] Figure 13 It is an exploded cross-sectional view showing the state in which the clamping component is pressed into the connection port of the output busbar.

[0022] Figure 14 This is an enlarged cross-sectional view showing another example of using an O-ring to waterproof the clamping member, output busbar, and the fixed part.

[0023] Figure 15 yes Figure 14 The exploded cross-sectional view of the waterproof structure is shown.

[0024] Figure 16 This is an enlarged cross-sectional view showing another example of an external output terminal.

[0025] Figure 17 This is an enlarged cross-sectional view showing an example of the waterproof construction of the external output terminal of the battery pack involved in the comparative example.

[0026] Figure 18 yes Figure 17 The exploded cross-sectional view of the waterproof structure is shown. Detailed Implementation

[0027] First, one aspect of the present invention will be explained. In battery packs housing a battery assembly containing numerous battery cells, to allow the external output terminals to be exposed from the outer casing, there are solutions where the external output terminals are fixed to the outer casing with a waterproof structure. As such a battery pack, a solution has been developed that uses a clamping nut on the external output terminals. Figure 17 and Figure 18The image shows an example of the waterproof construction of the external output terminals in the battery pack.

[0028] The waterproof construction shown in these figures involves pressing and securing a clamping nut 95 into the connection port 92 of the output busbar 91, and providing a through hole 94 in the opening of the outer housing 93 to guide the clamping nut 95. To provide a waterproof configuration for the clamping nut 95 on the outer housing 93, the clamping nut 95 shown in the figures has an annular outer peripheral groove 96 along its outer circumferential surface, and an O-ring 97 is positioned in this groove 96. The O-ring 97, positioned on the outer peripheral surface of the clamping nut 95, abuts against the opening end face of the through hole 94 in the outer housing 93 while fixing the output busbar 91 to the inner surface of the outer housing 93, and elastically deforms, thereby sealing the contact portion that contacts the opening end face of the through hole 94, thus achieving a waterproof construction.

[0029] In the above construction, because the clamping nut 95 needs to be machined into a special shape, it requires special ordering, which increases manufacturing costs. Furthermore, in... Figure 17 and Figure 18 In the illustrated configuration, since an O-ring 97 is disposed in the outer peripheral groove 96 on the outer peripheral surface of the clamping nut 95, it is impossible to elastically deform the O-ring 97 while forcefully pressing it against the outer peripheral surface of the clamping nut 95 and the opening end face of the through hole 94 of the outer housing 93. This results in a problem where a strong, tight seal cannot be achieved. The present invention was developed to solve this problem.

[0030] An embodiment of the present invention relates to a battery pack comprising: a battery assembly having a plurality of battery cells; an outer casing for housing the battery assembly; an external output terminal exposed outside the outer casing; and an output busbar for fixing the external output terminal to a first end and connecting the output terminal of the battery assembly to a second end. The external output terminal is composed of a clamping member having a cylindrical shape. The output busbar presses the fixed end of the clamping member into a connection opening at the first end, fixing the clamping member in a vertical position, and the clamping member closes the fixed end side. A portion of the outer casing is designated as a fixing part for fixing the external output terminal. A terminal insertion port, through which the clamping member passes, is opened in the fixing part. A chamfer is provided along the opening edge of at least one of the opening edges of the opposing connection openings and the opening edges of the terminal insertion port. Furthermore, an annular rubber-like elastomer through which the clamping member is inserted is disposed at the opening edge of the connection opening of the output busbar and at the boundary with the clamping member. Insert the clamping member into the terminal insertion port. With the output busbar fixed to the fixed part, the external output terminal is fixed to the outer housing with a waterproof structure by sealing the opening edge of the connection port, the opening edge of the terminal insertion port and the outer peripheral surface of the clamping member through an elastically deformable rubber-like elastomer.

[0031] The advantage of the above structure is that, without special processing of the clamping member, the output busbar with the clamping member fixed to it can be reliably waterproofed by simply processing it using a common clamping member. In particular, according to the above structure, since a chamfer is provided at least one of the opening edges of the connection port of the output busbar and the terminal insertion port of the fixed part, the annular rubber-like elastomer held by the opening edges of the connection port and the terminal insertion port can be positioned while being pressed against the outer circumferential surface of the clamping member along the chamfer, thereby reliably sealing it with the rubber-like elastomer. Therefore, the advantage of the above structure is that it can reliably provide a waterproof structure while reducing manufacturing costs through a simple and easy-to-use construction.

[0032] In other embodiments of the present invention, the clamping member is a bottomed nut member with a fixed end blocked, and the internal thread of the nut member is used as an external connection part of the external output terminal.

[0033] According to the above structure, since the clamping member is set as a bottomed blind hole type nut member with the fixed end blocked, and the internal thread part of the nut member is set as a female type terminal as the external connection part of the external output terminal, the external connection can be easily and simply performed by connecting the connection terminal via a bolt or the like with an external thread.

[0034] In other embodiments of the present invention, the clamping member is a nut member with a fixed end opening. The fixed end is closed by screwing the bolt member into the nut member from the fixed end side. The external thread of the bolt member protrudes from the nut member and serves as an external connection part of the external output terminal.

[0035] According to the above structure, the clamping member is a through-hole type nut member with a fixed end opening. The bolt member is screwed into the clamping member from the fixed end side to close the fixed end. Furthermore, the external thread of the screwed-in bolt member is set as a male terminal as the external connection part of the external output terminal. Therefore, the connection terminal can be connected via a nut or the like with an internal thread, thereby making external connection simple and easy.

[0036] In other embodiments of the present invention, the battery pack may be configured as an O-ring, with the width of the chamfered portion being greater than the radius in the cross-section of the O-ring, and the depth of the chamfered portion being less than the diameter in the cross-section of the O-ring.

[0037] According to the above structure, since the rubber-like elastomer, i.e., the O-ring, can reliably deform elastically while being guided to the chamfered portion, it is possible to fix the clamping member and the output busbar to the fixed portion while reliably constructing a waterproof structure.

[0038] In other embodiments of the present invention, the battery pack may be configured as an O-ring, such that the area of ​​the chamfered region in the cross-section of the chamfered portion is smaller than the cross-sectional area of ​​the O-ring.

[0039] Based on the above structure, since the rubber-like elastomer, i.e., the O-ring, can reliably deform elastically and be pressed while being guided to the chamfered portion, it is possible to reliably fix the external output terminals and output busbars to the outer housing while making them waterproof.

[0040] In other embodiments of the present invention, the battery pack may have an outer casing with a recess on the surface of the casing for configuring an external output terminal, and the bottom surface of the recess may be used as a fixed part.

[0041] According to the above structure, since the bottom surface of the recess provided on the surface of the outer housing is set as the fixed part to fix the output busbar, the connection part connected to the external output terminal can be protected by configuring the connection part of the output busbar to be further inside than the surface of the housing.

[0042] In other embodiments of the present invention, the depth of the recess is made greater than the amount of protrusion of the external output terminal protruding from the fixed portion.

[0043] According to the above structure, since the depth of the recess provided in the outer housing is greater than the protrusion of the external output terminal protruding from the fixed part, the external output terminal can be disposed inside the recess without protruding from the housing surface, thereby protecting the external output terminal while making the appearance aesthetically pleasing.

[0044] (Implementation Method 1)

[0045] exist Figures 1-10 This illustration shows a battery pack according to an embodiment of the present invention. In these figures, respectively, Figure 1 A 3D diagram showing the battery pack. Figure 2 express Figure 1 The exploded 3D view of the battery pack shown. Figure 3 Indicates viewing from below Figure 2 The image shows an exploded perspective view of the back of the battery pack. Figure 4 This is an exploded 3D view of the battery pack. Figure 5 A block diagram representing the battery pack. Figure 6 This is a top view of the battery pack. Figure 7 as well as Figure 8 express Figure 6 The cross-sectional diagrams along line VII-VII and line VIII-VIII are shown in the figure. Figure 9 express Figure 7The exploded cross-sectional view shown in these figures shows a battery pack comprising: a battery pack 2 having a plurality of battery cells 1; an outer housing 3 for housing the battery pack 2; an external output terminal 8 exposed from the outer housing 3; and an output busbar 81 that fixes the external output terminal 8 to a first end 81A and connects the output terminal 15 of the battery pack 2 to a second end 81B.

[0046] (Battery pack 2)

[0047] like Figures 2-4 As shown, the battery pack 100 houses multiple battery cells 1 as a battery assembly 2 within the outer casing 3. Multiple battery cells 1 are arranged in a given configuration to form battery blocks 10, and these battery blocks 10 are connected to form the battery assembly 2. The battery pack 100 shown in the figure stacks and connects two battery blocks 10 in a vertically upright position in the front-to-back direction to form the battery assembly 2. The battery assembly 2 connects the two stacked battery blocks 10 via a connecting member (not shown).

[0048] (Battery Unit 1)

[0049] Battery cell 1 is a non-aqueous electrolyte secondary battery cell such as a lithium-ion battery. However, this invention does not limit battery cell 1 to lithium-ion batteries; it can use other non-aqueous electrolyte secondary batteries, nickel-metal hydride batteries, and all currently used and future-developed secondary batteries. Figure 4 Battery cell 1 is a cylindrical battery with both ends serving as electrode faces. However, the battery pack of the present invention does not specifically limit the battery to a cylindrical shape. This is because battery cell 1 can also use rechargeable prismatic batteries, etc. The cylindrical battery houses the electrodes and electrolyte within a cylindrical metal casing. The metal casing is configured with a hermetically sealed structure in which a sealing plate is airtightly fixed to the opening of an outer can that seals the bottom. The outer can is manufactured by pressing a metal sheet. The sealing plate is hermetically fixed by riveting it to the periphery of the opening of the outer can through a gasket of insulating material. The prismatic battery has positive and negative electrode terminals insulated from the sealing plate that seals the opening of the metal casing.

[0050] (Battery Block 10)

[0051] The battery block 10 arranges multiple battery cells 1 in a parallel orientation, and the terminal faces of each battery cell 1 are arranged on the same plane. The battery block 10 uses a plastic battery holder 12 to hold the multiple battery cells 1 in a fixed position. Figure 4 The battery block 10 houses 154 cylindrical batteries in the battery holder 12, and arranges 11 battery units 1 in a single row. The battery block 10 sets each battery unit 1 in a parallel position, aligns the electrode faces of the battery units 1 on the same plane, and connects the electrode faces on the same plane to the lead plate 11.

[0052] (Leaderboard 11)

[0053] The battery block 10 uses multiple lead plates 11 to connect multiple battery cells 1 in parallel. Figure 4 The lead plate 11 shown is configured as a stacked structure consisting of a connecting lead plate 11A having a connection portion for connecting to the electrode faces of multiple battery cells 1, and a current-carrying lead plate 11B for reducing the current-carrying resistance between battery cells 1 connected in parallel or series. The connecting lead plate 11A is connected to the electrode faces using methods such as laser welding, spot welding, or ultrasonic welding. Furthermore, the battery block 10 connects multiple battery cells 1 that are connected in parallel to each other in series via a busbar 14 disposed on the side of the battery holder 12. Figure 4 The battery block 10 connects 154 battery cells 1 in a 22-parallel and 7-series configuration. However, the battery block does not limit the number of battery cells or their connection configuration to the above specifications. The battery block can perform various changes to the number of connected battery cells and their connection configuration.

[0054] (Battery bracket 12)

[0055] Figure 4 The battery holder 12 is configured to arrange multiple battery cells 1 in fixed positions. Figure 4 The battery holder 12 is integrally formed by molding an insulating plastic material to hold the insertion cylinder 13 of multiple battery cells 1 in a fixed position. The insertion cylinder 13 holds the battery cells 1 placed therein in a fixed position. The battery holder 12 in the figure is a cylindrical battery cell, and the insertion cylinder 13 is shaped to insert and hold the cylindrical battery cell in a fixed position. The battery holder 12 in the figure arranges 154 battery cells 1 in a stacked arrangement, in which 11 cells are arranged side by side in one column in the left-right direction, and arranged in 14 layers in the top-bottom direction. Furthermore, battery cells 1 located in the top-bottom position are arranged between the valleys of adjacent battery cells 1 on the left and right sides.

[0056] like Figure 4As shown, the battery holder 12 is formed by dividing it into a pair of unit holders 12A and 12B. Each unit holder 12A and 12B constituting the battery holder 12 is provided with an insertion tube 13 into which a battery unit 1 is inserted in a parallel position. The insertion tube 13 is open at both ends, exposing the electrode faces of the cylindrical battery inserted therein, allowing the lead plate 11 to be connected to the electrode faces. The insertion tube 13 of the unit holders 12A and 12B is about half the length of the battery unit 1 that can be inserted. Each battery unit 1 inserts half of its length into one unit holder 12A and the remaining half into the other unit holder 12B, thereby positioning it in a fixed position on the battery holder 12. The battery holder 12 constructed in the above way has the following advantages: by inserting the battery unit 1 into the insertion tube 13 of the unit holders 12A and 12B which are divided into two parts, multiple battery units 1 can be reliably held in a fixed position.

[0057] like Figures 2-5 As shown, the battery pack 2 connects two battery cells 10 arranged in series. The two battery cells 10 are connected in series via a connecting busbar 16 disposed on the lower surface. The connecting busbar 16 connects to the output lead portion 11b, which is led out from the lead plate 11 connected to the positive and negative output sides of the multiple battery cells 1 connected in series, and extends to the lower side of the battery cell 10. Furthermore, the battery pack 2 has positive and negative output terminals 15 disposed on the upper surface. The positive and negative output terminals 15 are metal plates stacked on the output lead portion 11a extending to the upper side of the battery cell. The positive and negative output terminals 15 of the battery pack 2 are connected to an external output terminal 8 via an output busbar 81.

[0058] Furthermore, although not shown, the battery pack may also include a circuit board. The circuit board can be mounted on a fixed position within the outer casing via a board support. For example, the board support can be positioned between the upper surface of the battery pack and the outer casing, with the circuit board disposed on its inner side. The circuit board can mount electronic components (not shown) that connect to the battery cells to implement protection circuits for the battery cells. These protection circuits can be configured as: circuits to prevent overcharging or over-discharging of the battery cells; or circuits to prevent overcurrent; or circuits to cut off current in the event of an abnormal temperature rise.

[0059] (Outer casing 3)

[0060] The outer casing 3 is designed as a rectangular box shape. The outer casing 3 is made of a component with excellent insulation properties, such as polycarbonate, PC-ABS alloy, or other resins. Figure 2 and Figure 3The outer casing 3 shown is divided into two parts, a main casing 3A and a cover casing 3B, in the middle of the upper and lower sections. The main casing 3A and cover casing 3B are designed as containers with a main panel 41 and a side panel 42 forming peripheral walls 40 around the end panel 43, creating a storage section 34 for housing the battery pack 2. The peripheral walls 40A and 40B, which are connected to the end panel 43, have different heights, thus making the main casing 3A deeper than the cover casing 3B. The main casing 3A and cover casing 3B are formed into a cylindrical shape by connecting the main panel 41 and the side panel 42 at both sides, and the end panel 43 is connected to one end face, while the other end face is an opening, thus forming a deep container shape.

[0061] Figures 1-3 The outer casing 3 shown is provided with multiple rows of grooves 44 formed on the surfaces of the main panel 41 and side panels 42, which serve as peripheral walls 40. The multiple grooves 44 extend parallel to each other in the height direction of the peripheral wall 40. The outer casing 3 in the figure has grooves 44 provided throughout the peripheral wall 40, making the outer casing 3 lightweight and increasing the surface area, thereby improving the heat dissipation characteristics of the outer casing 3. The main casing 3A and the cover casing 3B have multiple rows of grooves 44 extending from the end panel 43 towards the opening, but not at the opening edge; instead, flanges 45 and 46 are provided along the opening edge. The main casing 3A and the cover casing 3B are connected to each other by opposite flanges 45 and 46 connected by fastening screws 18. Figure 3 As shown, the cover housing 3B has an insertion hole 46a for inserting the fastening screw 18 on the flange portion 46, and the main body housing 3A has a flange portion 45 for screwing in the fastening screw 18.

[0062] Furthermore, the main body shell 3A and the cover shell 3B are connected by a waterproof structure at opposite opening edges separated by a gasket member 19. Figure 2 The liner member 19 shown is a rubber liner of a given thickness, which is approximately rectangular in shape when viewed from above along the open end faces of the main body housing 3A and the cover housing 3B, and is arranged along the longitudinal groove 47 provided on the open end face of the main body housing 3A. Since the main body housing 3A and the cover housing 3B are connected by fastening screws 18 at positions opposite to the groove 44 provided on the peripheral wall 40, therefore, Figure 2The gasket member 19 has an inwardly U-shaped meandering portion 19A at the position opposite to the groove 44, i.e., at the position where the fastening screw 18 is inserted. This allows the fastening screw 18 to be screwed onto the outside of the gasket member 19, preventing water ingress at the screw fastening portion. The gasket member 19 is positioned in the longitudinal groove 47 of the open end face of the main body housing 3A. With the gasket member 19 clamped by the open end face of the cover housing 3B, the fastening screw 18, inserted through the insertion hole 46a of the flange portion 46 of the cover housing 3B, is screwed into the flange portion 45 of the main body housing 3A, thereby connecting them with a watertight structure. The short groove 44 formed along the entire length of the cover housing 3B also serves as a tool clearance for guiding the screwdriver when screwing in the fastening screw 18.

[0063] (recess 20)

[0064] Furthermore, the outer casing 3 exposes the external output terminals 8 for outputting the positive and negative outputs of the built-in battery pack 2 to the outside. Figure 1 The outer housing 3 shown has the external output terminal 8 exposed on the upper surface of the cover housing 3B. The outer housing 3 has a recess 20 that is recessed inward from the housing surface, and the external output terminal 8 is disposed inside this recess 20. Figure 1 , Figure 6 ,as well as Figure 7 As shown, the recess 20 is a quadrangular prism, with a depth (h) sufficient to completely accommodate the external output terminal 8 protruding from the bottom surface. That is, the recess 20 is formed such that its depth (h) is greater than the amount of protrusion of the external output terminal 8 positioned to protrude from the bottom surface. This structure prevents the external output terminal 8 from protruding from the housing surface, resulting in a neat and aesthetically pleasing appearance. Furthermore, it has the advantage of protecting the external output terminal 8 by housing it inside the recess 20. It is not necessary for the outer housing to have a recess on its surface and for the external output terminal to be positioned therein; the external output terminal can also be fixedly mounted on the surface plate forming the housing surface. The external output terminal 8 is fixed to the outer housing 3 with a waterproof structure. The waterproof structure of this part will be described in detail below.

[0065] (Fixed part 21)

[0066] The outer housing 3 has a portion of the surface plate set as the fixed part 21 for fixing the external output terminal 8. Figures 7-9The outer housing 3 shown has a fixed portion 21 on the bottom surface of the recess 20 for fixing the external output terminal 8. The fixed portion 21 has an opening 22 for the external output terminal 8, i.e., the cylindrical clamping member 80, to pass through. The terminal insertion port 22 is circular along the outer shape of the clamping member 80, and its inner diameter is approximately equal to or slightly larger than the outer diameter of the clamping member 80. If the inner diameter of the terminal insertion port 22 is too large, the gap between the opening edge of the terminal insertion port 22 and the outer peripheral surface of the clamping member 80 becomes larger, making waterproofing difficult. Therefore, the gap between the opening edge of the terminal insertion port 22 and the outer peripheral surface of the clamping member 80 is preferably 1 mm or less, and more preferably 0.1 mm or less.

[0067] Furthermore, the fixed portion 21 is provided with an internally threaded hole 24 for screwing in a fixing screw 26 that passes through the output busbar 81 in order to fix the output busbar 81 on its lower surface. The internally threaded hole 24 opens into the lower surface of the fixed portion 21 for the insertion port of the fixing screw 26, and the internally threaded hole 24 is formed deeper by providing a protrusion 25 that protrudes from the upper surface of the fixed portion 21, so that the fixing screw 26 screwed into the fixed portion 21 can be screwed in deeper without passing through, thereby securing it. The internally threaded holes 24 are provided at four equal intervals around the terminal insertion port 22.

[0068] (External output terminal 8)

[0069] The external output terminal 8 is composed of a clamping member 80 with a cylindrical shape. In this specification, the clamping member 80 refers to a member that is fixed by pressing one end into a through hole provided in a metal plate. For example, a nut member called a clamping nut or clamping spacer can be given. However, the present invention does not limit the clamping member 80 to the above, but can be other members that can be pressed into and fixed to the output busbar 81. The shape and fixing method of the clamping member may vary depending on the manufacturer. In the present invention, regardless of these specifications, a commonly used clamping member is used in the external output terminal and fixed to the outer housing with a waterproof structure.

[0070] A cylindrical clamping member 80 is fixed vertically to the connection port 82 at the opening of the output busbar 81. Furthermore, the clamping member 80 closes the fixed end 80x of the output busbar 81. The clamping member 80 shown in the figure is a cylindrical nut member, specifically a bottomed nut member 80A that closes the fixed end 80x of the output busbar 81. For example, a blind-hole type clamping nut can be used as such a clamping member. The clamping member 80 is made of stainless steel, for example, SUS304. Alternatively, the clamping member can be made of a metal other than stainless steel. The metal clamping member 80 is pressed into the connection port 82 at the opening of the metal output busbar 81 and thus fixed. In this configuration, since the clamping member 80 is a bottomed nut member 80A that closes the fixed end 80x, the internal thread portion 80a of the nut member 80A serves as the external connection portion of the external output terminal 8. The external output terminal 8 of this shape is a female terminal, and is connected to a connecting wire that is externally connected via a bolt or the like having an external thread.

[0071] (Output bus bar 81)

[0072] like Figure 7 As shown, the output busbar 81 is disposed inside the outer housing 3, connecting the output terminal 15 of the battery pack 2 to the external output terminal 8. The output busbar 81 is a conductive metal plate with a given thickness, for example 1 to 2 mm. The external output terminal 8 is fixed at one end, namely the first end 81A, and the other end, namely the second end 81B, is connected to the output terminal 15 of the battery pack 2. For example, a nickel-plated aluminum plate or a copper plate can be used as such a metal plate. Figure 7 and Figure 10 The output busbar 81 shown has its overall shape shaped like a crank by bending the first end 81A and the second end 81B in opposite directions relative to the middle portion 81C. This output busbar 81 has the advantage that by connecting the first end 81A and the second end 81B, which are bent in opposite directions, via the middle portion 81C, the first end 81A and the second end 81B can be connected while being separately positioned vertically. Furthermore, the output busbar 81 shown in the figure has a U-shaped section in the middle portion 81C, which serves as an elastic deformation section 86. This elastic deformation section 86 has the advantage of absorbing tolerances and positional deviations of the first end 81A, which is fixed to the inner surface of the cover housing 3B, and the second end 81B, which is connected to the output terminal 15 of the battery pack 2, through elastic deformation. The elastic deformation section can also be configured differently from the U-shaped section.

[0073] like Figures 7-9As shown, the output busbar 81 has an opening at the first end 81A of the fixed clamping member 80 for pressing into the clamping member 80. The connection opening 82 is formed to the inner diameter of the fixed end 80x of the clamping member 80 that can be pressed into it. Furthermore, Figures 10-13 The output busbar 81 shown has a chamfered portion 83 on the surface opposite to the fixed portion 21, where the opening edge of the connection port 82 is chamfered along the opening edge. The chamfered portion 83 is cut off by an inclined surface 83A, and the chamfered area in the cross-section ( Figure 11 The cross-sectional shape (shown in gray shading) is set to approximately triangular. Thus, as... Figure 11 and Figure 12 As shown, the chamfered portion 83 formed at the opening edge of the connection port 82 serves as a positioning part for the annular rubber-like elastomer 70 held between the output busbar 81 and the fixed part 21. Thus, the configuration of providing the chamfered portion 83 at the opening edge of the connection port 82 opening into the output busbar 81 is suitable because it allows the chamfered portion 83 to simultaneously serve as a positioning part for the annular rubber-like elastomer 70 while removing metal burrs generated at the opening edge during the process of removing metal burrs from the metal plate opening the connection port 82.

[0074] Furthermore, such as Figure 10 As shown, the output busbar 81 has an opening around the connection port 82 with through holes 84 for fixing the first end 81A of the clamping member 80 to the fixing part 21 through which the fixing screw 26 passes. These through holes 84 are provided at four equal intervals around the connection port 82, opposite to the internal threaded hole 24 provided in the fixing part 21.

[0075] Furthermore, the output busbar 81 has a connection hole 85 at its second end 81B for inserting a connection bolt 27 for connecting to the output terminal 15 of the battery pack 2. Figure 7 This indicates that the output busbar 81 is connected to the output terminal 15 on the negative side of the battery pack 2. The output busbar 81 is connected to the output terminal 15 of the battery pack 2 via a current cutoff element 17. For example... Figure 10 As shown, the connection hole 85 is designed as an elongated hole to allow for positional deviation of the connection portion.

[0076] (Rubber-like elastomer 70)

[0077] To secure the output busbar 81, to which the clamping member 80 is fixed, to the fixed portion 21 in a watertight manner, an annular rubber-like elastomer 70 is disposed between the output busbar 81 and the fixed portion 21 along the outer peripheral surface of the clamping member 80. For example, an O-ring 70 containing silicone rubber or nitrile rubber can be used as such a rubber-like elastomer 70. Figure 12As shown, the O-ring 71, i.e., the rubber-like elastomer 70, fixes the output busbar 81 to the fixed part 21 while being disposed on the outside of the clamping member 80. The output busbar 81 is clamped by the fixed part 21 and elastically deformed, thereby sealing the clamping member 80 relative to the terminal insertion port 22 of the fixed part 21 with a watertight structure.

[0078] At this time, the O-ring 71, positioned in a fixed position by the chamfered portion 83 of the opening edge of the connection port 82 of the output busbar 81, is pressed by the opening edge of the terminal insertion port 22 of the fixed portion 21 and elastically deformed. Thus, the O-ring 71 positioned at the chamfered portion 83 of the connection port 82 is flattened along the inclined surface 83A of the chamfered portion 83 and pressed against the outer peripheral surface of the clamping member 80, thereby achieving an ideal seal. This is because the O-ring 71, pressed by the fixed portion 21, exerts a force that presses the outer peripheral surface of the clamping member 80 inwards due to the reaction force received from the inclined surface 83A when pressing the chamfered portion 83. In this way, the O-ring 71, i.e., the rubber-like elastomer 70, elastically deforms under the pressure of the terminal insertion port 22 of the fixed part 21, the inclined surface 83A of the chamfered part 83, and the outer peripheral surface of the clamping member 80, thereby ideally sealing these components and connecting them with a watertight structure.

[0079] As described above, in order to achieve ideal elastic deformation of the O-ring 71 for sealing, preferably, the chamfer 83 has a width (w) greater than the radius (r) in the cross-section of the O-ring 71, and a depth (d) less than the diameter (2r) in the cross-section of the O-ring 71. For example, the width (w) of the chamfer 83 can be set to r≤w≤2r, and the depth (d) can be set to r≤d≤2r. By setting the chamfer 83 to the above shape, the O-ring 71, which is pressed by the opening edge of the terminal insertion port 22 of the fixed part 21, can be reliably guided to the inside of the chamfer 83 and positioned. At the same time, it can be appropriately elastically deformed along the chamfer 83, thereby reliably pressing the outer peripheral surface of the clamping member 80.

[0080] The chamfered portion 83 formed as described above can have its chamfered cut surface set as an inclined surface 83A. Alternatively, the chamfered portion can have its chamfered cut surface set as a curved surface, such as a convex or concave surface. Furthermore, as... Figure 11 As shown in the enlarged cross-sectional view, the area of ​​the chamfered region (shown in gray shading in the figure) in the cross-section of the chamfered portion 83 can be set to be smaller than the cross-sectional area of ​​the O-ring 71 when it undergoes inelastic deformation. Therefore, the O-ring 71, pressed by the chamfered portion 83 of the output busbar 81, the outer peripheral surface of the clamping member 80, and the opening edge of the terminal insertion port 22 of the fixing portion 21, can elastically deform relative to each contact surface, reliably sealing each contact portion.

[0081] like Figure 11 As shown, regarding the O-ring 71 provided in the chamfered portion 83 of the connection port 82, after the clamping member 80 is fixed to the connection port 82 of the output busbar 81, the O-ring 71 is inserted through the clamping member 80 and disposed in the chamfered portion 83. Wherein, as Figure 13 As shown, the O-ring can also be disposed on the chamfered portion 83 during the process of pressing the clamping member 80 into the connection port 82 of the output busbar 81. Figure 13 The process is as follows: With the output busbar 81 placed on the support platform 78, which serves as a clamp, an O-ring 71 is positioned on the chamfered portion 83. Then, with the clamping member 80 inserted inside the O-ring 71, the pressing part 79 is used to press the clamping member 80 into the connection port 82. According to this method, during the process of pressing the clamping member 80 into the connection port 82, while the O-ring 71 pre-positioned on the chamfered portion 83 is rolled in, the outer peripheral surface of the clamping member 80 and the inclined surface 83A of the chamfered portion 83 can clamp and position the O-ring 71 in a fixed position. With the output busbar 81 fixed by pressing the clamping member 80 into the connection port 82, the O-ring is also fixed in a fixed position. In addition, in the example shown, an O-ring 71 is used as a ring-shaped rubber elastomer 70, but it is not limited to an O-ring. Rubber elastomers with similar cross-sectional shapes, such as triangular or polygonal cross-sections, that are slightly larger than the cross-sectional shape of the chamfered portion 83 can also be used.

[0082] The battery pack 100 described above uses the following process to fix the external output terminal 8 to the outer housing 3 in a waterproof manner.

[0083] (1) A connection port 82 is opened at a fixed position at the first end 81A of the output busbar 81. The connection port is opened by means of a punch or the like.

[0084] (2) The opening edge of the connection port 82 that opens into the output busbar 81 is chamfered to form a chamfered portion 83. This process can also be used to remove metal burrs generated at the opening edge when the connection port 82 is opened.

[0085] (3) The clamping member 80 is pressed into the connection port 82 of the output busbar 81 and fixed. The clamping member 80 is fixed in a vertical position relative to the output busbar 81. In this process, as Figure 13 As shown, the O-ring 71 can also be fixed in the fixed position of the chamfered part 83.

[0086] (4) such as Figure 9 As shown, the O-ring 71 is inserted through the clamping member 80 fixed to the output busbar 81 and disposed in the chamfered portion 83.

[0087] (5) Furthermore, such as Figure 9As shown, while the clamping member 80 is guided to the terminal insertion port 22 of the fixed part 21 which opens into the outer housing 3, the output busbar 81 is disposed on the lower surface of the fixed part 21.

[0088] (6) The output busbar 81 disposed on the lower surface of the fixed part 21 is fixed to the fixed part 21 by means of the fixing screw 26. The fixing screw 26 is screwed into the internal thread hole 24 of the fixed part 21 with the through hole 84 of the output busbar 81 through it, thereby fixing the output busbar 81 and the lower surface of the fixed part 21.

[0089] (7) For example Figure 12 As shown, in this state, the O-ring disposed on the chamfered portion 83 is pressed by the relatively close output busbar 81 and the fixing portion 21, thereby elastically deforming and sealing itself in close contact with the chamfered portion 83 of the output busbar 81, the opening edge of the terminal insertion port 22 of the fixing portion 21, and the outer peripheral surface of the clamping member 80.

[0090] As described above, the output busbar 81 is fixed to the fixed position inside the cover housing 3B. Then, after connecting the cover housing 3B to the main housing 3A and securing it with the fastening screws 18, the second end 81B of the output busbar 81 is connected to the output terminal 15 of the battery pack 2. During the process of connecting the output busbar 81 to the output terminal 15, Figure 7 In the middle, the connecting bolt 27 is inserted and screwed in through the opening cylindrical portion 48, which is integrally formed with the end panel 43 of the cover housing 3B and has an opening on the housing surface. After the output busbar 81 is connected to the output terminal 15 via the connecting bolt 27, the opening of the opening cylindrical portion 48 is watertightly sealed by the sealing member 49.

[0091] in addition, Figure 1 , Figure 2 as well as Figure 6 The outer housing 3 shown has recesses 20 at points 2 on the cover housing 3B to expose the positive and negative external output terminals 8, and the positive and negative external output terminals 8 are arranged there. The positive and negative external output terminals 8 are fixed with substantially the same structure, but the diameter of the clamping member 80 is set to different sizes for the external output terminals 8 on the positive side and the external output terminals 8 on the negative side. As a result, the user can correctly connect the positive and negative external output terminals 8 without misconnection. Figure 6 The battery pack 100 shown is connected to the positive side external output terminal 8 of the battery pack 2 via the output terminal 15 on the positive side. Figure 6 The nut component (shown in the lower left corner) is configured with an inner diameter of 12mm, and the external output terminal 8 on the negative side is connected to the output terminal 15 on the negative side of the battery pack 2. Figure 6 (Displayed in the upper right corner) is set as a nut component with an inner diameter of 8mm.

[0092] Furthermore, the external output terminal 8 on the negative side is connected to the current cut-off element 17 between it and the output terminal 15 of the battery pack 2. Figure 2 and Figure 7 The current-cutting element 17 shown is a fuse, which melts and cuts off the current when an overcurrent flows through the battery pack 2. Alternatively, a circuit breaker or similar device can be used instead of a fuse for the current-cutting element. Figure 7 The current cutting-off element 17 has lead portions 17B on both sides of the element body 17A. One lead portion 17B is connected to the second end 81B of the output busbar 81 via a connecting bolt 27, and the other lead portion 17B is connected to the output terminal 15 of the battery pack 2 via a connecting bolt 27.

[0093] (Other examples of waterproof construction)

[0094] In the above waterproof structure, a chamfered portion 83 is provided by chamfering the opening edge of the connection port 82 that opens into the output busbar 81. However, the chamfered portion can also be provided by chamfering the opening edge of the terminal insertion port that opens into the fixed portion 21. Figure 14 and Figure 15 The waterproof structure is shown. Regarding the waterproof structure shown in these figures, instead of providing a chamfered portion at the opening edge of the connection port 82 of the output busbar 81 where the clamping member 80 is fixed, the chamfered portion is provided at the opening edge of the terminal insertion port 22 opening into the fixed portion 21. In the fixed portion 21 shown in the figures, a chamfered portion 23 is provided by chamfering the opening edge of the terminal insertion port 22 along the opening edge in the surface opposite to the output busbar 81. The chamfered portion 23 is cut off by an inclined surface 23A, and its size and shape can be the same as the chamfered portion 83 provided in the aforementioned output busbar.

[0095] In the above waterproof structure, the O-ring 71 is also elastically deformed by being pressed by the output busbar 81 while it is positioned in a fixed position by the chamfered portion 23 located at the opening edge of the terminal insertion port 22 of the fixed portion 21. Thus, the O-ring 71 located at the chamfered portion 23 of the terminal insertion port 22 is flattened along the inclined surface 23A of the chamfered portion 23 and pressed against the outer peripheral surface of the clamping member 80, thereby achieving an ideal seal. This is because the O-ring 71 pressed by the output busbar 81 exerts a force that presses the outer peripheral surface of the clamping member 80 inwards due to the reaction force received from the inclined surface 23A when pressing the chamfered portion 23. In this waterproof structure, the O-ring 71, i.e., the rubber-like elastomer 70, also achieves ideal sealing of these components by elastically deforming under pressure from the chamfered portion 23 of the opening edge of the terminal insertion port 22 provided in the fixed portion 21, the output busbar 81, and the outer peripheral surface of the clamping member 80, thereby connecting them in a watertight manner. Furthermore, in the battery pack of the present invention, chamfered portions can also be provided on both the output busbar and the fixed portion.

[0096] (Other examples of external output terminals)

[0097] The external output terminal 8 described above is composed of a bottomed nut member 80A, i.e., a clamping member 80, and the internal thread portion 80a provided on the inner side of the nut member 80A is configured as the external connection portion of the external output terminal 8. Furthermore, the present invention can also configure the external output terminal as... Figure 16 The structure shown.

[0098] Figure 16 The external output terminal 8 shown has a clamping member 80 configured as a nut member 80B with an open fixed end 80x. A bolt member 87 is screwed into the nut member 80B from the fixed end 80x side, closing the fixed end 80x through the head of the bolt member 87. The external thread 87a of the bolt member 87 protrudes from the nut member 80B, serving as an external connection portion. In another configuration, the external output terminal 8 has a clamping member 80 configured as a through-hole type nut member 80B with an open fixed end 80x. A bolt member 87 is screwed into the nut member 80B from the fixed end 80x side, thereby serving as an external connection portion of the external output terminal 8. This type of external output terminal 8 is a male terminal, connected to a wire of an externally connected terminal via a nut or the like with an internal thread.

[0099] Considering the load on the O-ring, the process of screwing the nut member 80B with the open fixed end 80x into the bolt member 87 from the fixed end 80x side is preferably set as a pre-process before fixing the nut member 80B to the fixed part 21. Furthermore, in the process of screwing the bolt member 87 into the nut member 80B and fixing it, it is preferable to reliably seal the fixed end 80x of the open nut member 80B with the bolt member 87 by using a sealing member such as sealing tape. Figure 16 The chamfered portion 83 for positioning the O-ring 71 is provided at the opening edge of the connection port 82 of the output busbar 81, but it can also be provided at the opening edge of the terminal insertion port 22 of the fixed portion 21 as described above.

[0100] Industrial availability

[0101] The present invention relates to a battery pack used as a power source for electric vehicles, or for electric heavy equipment, forklifts, etc., and in particular, it enables the effective use of a battery pack in which many battery cells are housed in an outer casing.

[0102] Explanation of reference numerals in the attached figures

[0103] 100… battery pack

[0104] 1… Battery cell

[0105] 2… Battery pack

[0106] 3…Outer casing

[0107] 3A…Main body shell

[0108] 3B…Cover housing

[0109] 8…External output terminals

[0110] 10… battery blocks

[0111] 11…leadboard

[0112] 11A…Connector Leads Board

[0113] 11B…Power Leadboard

[0114] 11a… Output lead section

[0115] 11b… Output lead section

[0116] 12… Battery bracket

[0117] 12A, 12B... Unit bracket

[0118] 13… Insertion tube

[0119] 14…Busbar

[0120] 15… Output terminals

[0121] 16…Connecting busbars

[0122] 17… Current interruption element

[0123] 17A…Component Body

[0124] 17B…lead section

[0125] 18… Fastening screws

[0126] 19… Liner components

[0127] 19A… Detour Section

[0128] 20…concave

[0129] 21…fixed part

[0130] 22…Terminal insertion port

[0131] 23… Chamfered section

[0132] 23A… Inclined surface

[0133] 24… Internal threaded hole

[0134] 25…protrusion

[0135] 26… Fixing screws

[0136] 27… connecting bolts

[0137] 34…Storage Department

[0138] 40, 40A, 40B... Zhou Bi

[0139] 41…Main Panel

[0140] 42…Side panel

[0141] 43…End panel

[0142] 44…groove section

[0143] 45…Flange portion

[0144] 46…Flange portion

[0145] 46a… Through-hole

[0146] 47…Longitudinal groove

[0147] 48…Open cylindrical section

[0148] 49……Blocking components

[0149] 70…rubber-like elastomer

[0150] 71…O ring

[0151] 78… Support Platform

[0152] 79… Pressing section

[0153] 80… clamping components

[0154] 80A, 80B... Nut components

[0155] 80a…Internal thread section

[0156] 81… Output Busbar

[0157] 81A…1st end

[0158] 81B…Second end

[0159] 82…Connection Port

[0160] 83… Chamfered section

[0161] 83A… Inclined surface

[0162] 84… Through-hole

[0163] 85…Connecting hole

[0164] 86…Elastic Deformation Section

[0165] 87… Bolt components

[0166] 87a…External thread section

[0167] 91… Output bus bar

[0168] 92…Connection Port

[0169] 93…Outer casing

[0170] 94… Through hole

[0171] 95… tightening nut

[0172] 96… peripheral groove

[0173] 97…O ring

[0174] 98… Fixing screw.

Claims

1. A battery pack, comprising: The battery pack has multiple battery cells; An outer casing is provided to house the battery pack. External output terminals are configured to be exposed outside the outer housing; and The output busbar fixes the external output terminal to the first end and connects the output terminal of the battery pack to the second end. The external output terminal is composed of a clamping member with a cylindrical shape. The output busbar presses the fixed end of the clamping member into the connection port open at the first end, vertically fixing the clamping member, and the clamping member closes the fixed end. The outer housing has a portion of the surface plate designated as a fixing part for securing the external output terminals, and the fixing part has an opening for a terminal insertion port through which the clamping member passes. A chamfer is provided along the opening edge of at least one of the opening edges of the opposing connector and the terminal insertion port. Furthermore, an annular rubber-like elastomer, through which the clamping member is inserted, is disposed at the opening edge of the connection port of the output busbar and at the boundary of the clamping member. When the clamping member is inserted into the terminal insertion port, and the output busbar is fixed to the fixed part, the opening edge of the connection port, the opening edge of the terminal insertion port and the outer peripheral surface of the clamping member are sealed by the elastically deformable rubber-like elastomer, thereby fixing the external output terminal to the outer housing in a waterproof structure.

2. The battery pack according to claim 1, wherein, The clamping member is a bottomed nut member with the fixed end blocked, and the internal thread of the bottomed nut member is used as the external connection part of the external output terminal.

3. The battery pack according to claim 1, wherein, The clamping member is a nut member with an open fixed end. The bolt member is screwed into the open nut member from the fixed end side to close the fixed end. The external thread of the bolt member protrudes from the open nut member, and the external thread of the bolt member serves as the external connection part of the external output terminal.

4. The battery pack according to any one of claims 1 to 3, wherein, The rubber-like elastomer is an O-ring, the width of the chamfer is greater than the radius in the cross-section of the O-ring, and the depth of the chamfer is less than the diameter in the cross-section of the O-ring.

5. The battery pack according to any one of claims 1 to 3, wherein, The rubber-like elastomer is an O-ring, and the area of ​​the chamfered region in the cross-section of the chamfered portion is smaller than the cross-sectional area of ​​the O-ring.

6. The battery pack according to claim 1, wherein, The outer housing has a recess on its surface for arranging the external output terminal, and the bottom surface of the recess is used as the fixed part.

7. The battery pack according to claim 6, wherein, The depth of the recess is greater than the protrusion of the external output terminal that protrudes from the fixed portion.

8. A battery pack comprising: The battery pack has multiple battery cells; An outer casing is provided to house the battery pack. External output terminals are configured to be exposed outside the outer housing; and The output busbar fixes the external output terminal to the first end and connects the output terminal of the battery pack to the second end. The external output terminal is a clamping component with a cylindrical shape. The output busbar presses the fixed end of the clamping member into the connection port open at the first end, vertically fixing the clamping member, and the fixed end of the clamping member is closed. The outer housing has a portion of its surface designated as a fixing part for securing the external output terminals, and the terminal insertion port of the clamping member passes through the opening in the fixing part. A chamfer is provided along the opening edge of at least one of the opening edges of the opposing connector and the terminal insertion port. Furthermore, near the boundary between the opening edge of the connection port of the output busbar, the opening edge of the terminal insertion port, and the clamping member, an annular rubber-like elastomer that is inserted through the clamping member is disposed. When the clamping member is inserted into the terminal insertion port, and the output busbar is fixed to the fixed part, the opening edge of the connection port, the opening edge of the terminal insertion port, and the outer peripheral surface of the clamping member are sealed by the elastically deformable rubber-like elastomer.

9. The battery pack according to claim 8, wherein, The clamping member is a bottomed nut with the fixed end blocked, and the internal thread of the bottomed nut is set as a female terminal of the external output terminal.

10. The battery pack according to claim 8, wherein, The clamping member is a nut with an open fixed end, which closes the fixed end by tightening the head of a bolt to the open nut. The external thread of the bolt protrudes from the opening of the nut member. The external thread of the bolt is configured as a male terminal of the external output terminal.

11. The battery pack according to any one of claims 8 to 10, wherein, The cross-sectional shape of the chamfered area in the cross-section of the chamfered portion is approximately triangular. The rubber-like elastomer is an O-ring. In the cross-section, the width of the chamfer is greater than the radius of the O-ring in the cross-section, and the depth of the chamfer is less than the diameter of the O-ring in the cross-section.

12. The battery pack according to any one of claims 8 to 11, The rubber-like elastomer is an O-ring. The cross-sectional area of ​​the O-ring is greater than the area of ​​the chamfered region in the cross-section of the chamfered portion.

13. The battery pack according to claim 8, wherein, The outer casing has a recess on its surface. The external output terminal is disposed in the recess, and the fixed part is the bottom surface of the recess.

14. The battery pack according to claim 13, wherein, The depth of the recess is greater than the amount of protrusion of the external output terminal that protrudes from the fixed portion.

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