Battery module

Abstract

A battery module (1) includes: an outer case (2); a battery assembly (3) housed in the outer case (2); an inlet (27) provided in a first end wall (21) of the outer case (2); a fan (5) mounted to an inner surface of the first end wall (21) to blow air drawn in through the inlet (27) to the inside of the outer case (2); a standing wall portion (6) having an opposing surface (61) opposite the fan (5) and a guide rib (62) projecting from a lower portion of the opposing surface (61) toward the fan (5); and a liquid leakage sensor (7) extending along the opposing surface (61) and arranged at least partially along the guide rib (62).

Description

Technical Field

[0001] This disclosure relates to a battery module. Background Technology

[0002] Patent document 1 discloses a battery module in which multiple battery cells are housed in a casing. The battery module has a fan to air-cool the heat-generating components such as the battery cells. The casing has an inlet and an outlet for cooling air to pass through, and the inlet and outlet are composed of multiple through holes.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: International Publication No. 2018 / 123573 Summary of the Invention

[0006] The problem the invention aims to solve

[0007] As one example of battery module usage, there is a situation where one or more battery modules are arranged on a shelf together with water-cooled electronic equipment. There is a concern that, in the event of a coolant leak, coolant could enter the battery module housing through the cooling air inlet or outlet. Other usage methods also raise concerns about liquid ingress.

[0008] The subject of this disclosure is to provide a battery module capable of detecting the entry of liquid with high precision.

[0009] Solution for solving the problem

[0010] One aspect of this disclosure provides a battery module comprising: an outer housing; a battery assembly housed within the outer housing; an inlet located on an end wall of the outer housing; a fan mounted on an inner surface of the end wall for blowing air drawn in through the inlet into the interior of the outer housing; a vertical wall having a facing surface opposite to the fan and a guide rib projecting from the lower portion of the facing surface toward the fan; and a leakage sensor extending along the facing surface and at least partially disposed along the guide rib.

[0011] The effects of the invention

[0012] According to this disclosure, a battery module capable of detecting the entry of liquid with high precision can be provided. Attached Figure Description

[0013] Figure 1 This is a perspective view of the battery module according to the first embodiment.

[0014] Figure 2 yes Figure 1 A partial cross-sectional view of the battery module.

[0015] Figure 3 yes Figure 1 An exploded 3D view of the battery module.

[0016] Figure 4 yes Figure 1 An exploded 3D view of the battery module.

[0017] Figure 5 yes Figure 4 An exploded perspective view of the fan, leakage sensor, and vertical wall section.

[0018] Figure 6 yes Figure 5 A three-dimensional view of the leakage sensor and the vertical wall section.

[0019] Figure 7 yes Figure 5 The leak sensor and the front view of the vertical wall section.

[0020] Figure 8 This is an exploded perspective view of the fan, leakage sensor, and vertical wall portion of the battery module in the second embodiment.

[0021] Figure 9 yes Figure 8 A three-dimensional view of the leakage sensor and the vertical wall section.

[0022] Figure 10 yes Figure 8 The leak sensor and the front view of the vertical wall section. Detailed Implementation

[0023] Hereinafter, the embodiments will be described with reference to the accompanying drawings. Furthermore, the same or corresponding elements are labeled with the same reference numerals in all the drawings, and repetition of detailed descriptions is omitted.

[0024] One embodiment of the battery module disclosed herein includes: an outer housing; a battery assembly housed within the outer housing; an inlet located on an end wall of the outer housing; a fan mounted on an inner surface of the end wall for blowing air drawn in through the inlet into the interior of the outer housing; a vertical wall having a facing surface opposite to the fan and a guide rib projecting from the lower portion of the facing surface toward the fan; and a leakage sensor extending along the facing surface and at least partially disposed along the guide rib.

[0025] According to the above structure, heat-generating components such as battery packs can be cooled using air blown out by the fan. On the other hand, it is possible that liquid may enter the interior from the outside of the outer casing through an inlet, carried by the airflow generated by the fan. The fan faces the opposing surface of the vertical wall. Therefore, the liquid drawn in by the fan is blown out towards the opposing surface. A leak sensor extends along this opposing surface. Therefore, when liquid is blown out by the fan, the leak sensor can effectively detect the entry of liquid.

[0026] When the amount of liquid entering is small, the liquid tends to be blown out in a mist. When the liquid is sprayed onto the leak sensor in a mist, the leak sensor may not be able to detect the liquid flow with high accuracy. However, the misty liquid is received by the opposite surface of the vertical wall, where it forms droplets and adheres. The droplets, while entraining droplets attached to the lower part of the opposite surface and increasing in size, flow downwards along the opposite surface due to their own weight. A guide rib is provided at the lower part of the opposite surface. The droplets are guided by the guide rib and accumulate at the lower part of the opposite surface. At least a portion of the leak sensor is arranged along such a guide rib, enabling it to detect the accumulated droplets effectively. That is, even when the amount of liquid entering is small, the leak sensor can detect the liquid entry with high accuracy.

[0027] Alternatively, in other embodiments of the battery module of this disclosure, the leakage sensor may include a lateral extension extending in the width direction along the lower edge of the opposite surface.

[0028] According to the above structure, since the lateral extension extends along the lower edge of the opposing surface in the width direction, droplets that accumulate at the lower part of the opposing surface can easily come into contact with the lateral extension. Therefore, the detection accuracy of liquid entry is improved.

[0029] Alternatively, in the battery module of other embodiments of this disclosure, the guide rib has a curved rib that bends toward the center side of the width direction of the opposite surface as it moves downward, and the lateral extension is configured along the inner surface of the curved rib.

[0030] According to the above structure, the droplets are guided towards the center and downwards of the opposite face along the inner surface of the curved rib. This allows the accumulated droplets to easily contact the laterally extended portion arranged along the inner surface of the curved rib. Therefore, the detection accuracy of liquid entry is improved.

[0031] Alternatively, in other embodiments of the battery module of this disclosure, the guide rib has an inclined rib that is inclined downward as it moves toward the center side in the width direction and is continuous with the upper end of the curved rib.

[0032] According to the above structure, the inclined ribs can collect droplets over a larger area of ​​the opposite surface and guide the collected droplets toward the curved ribs. Therefore, the amount of droplets that accumulate at the curved ribs, i.e., the amount of droplets that can contact the lateral extension, increases. Consequently, the detection accuracy of liquid entry is improved.

[0033] Alternatively, in other embodiments of the battery module disclosed herein, the leakage sensor may include: a first longitudinal extension extending upward from one end of the transverse extension in the width direction; and a second longitudinal extension extending upward from the other end of the transverse extension in the width direction.

[0034] According to the above structure, the presence of the first and second longitudinal extensions allows the leakage sensors to be distributed over a large area on opposite surfaces. Therefore, the detection accuracy of liquid ingress is improved. A portion of the liquid is directly blown into the first and second longitudinal extensions. Thus, even when a large amount of liquid enters, the first and second longitudinal extensions can sufficiently sense the liquid ingress before it drips, enabling rapid detection.

[0035] Alternatively, in the battery module of other embodiments of this disclosure, the guide rib has a first longitudinal rib and a second longitudinal rib that are separated from each other in the width direction and extend in the vertical direction, the first longitudinal extension being disposed along the inner surface of the first longitudinal rib, and the second longitudinal extension being disposed along the inner surface of the second longitudinal rib.

[0036] According to the above structure, droplets accumulate along the inner surface of the first or second longitudinal rib towards the lower part of the opposite surface. This allows the accumulated droplets to easily contact the first and second longitudinal extensions, which are arranged along the inner surface of the longitudinal ribs. Therefore, the detection accuracy of liquid entry is improved.

[0037] Alternatively, in the battery module of other embodiments of this disclosure, a cylindrical first sleeve is wound around the connection between the first longitudinal extension and the signal line, the upper end of the first longitudinal extension is bent toward the other side in the width direction, and the first sleeve extends from the first longitudinal extension toward the other side in the width direction along the upper edge of the opposite surface.

[0038] According to the above structure, the first sleeve is positioned along the upper edge of the opposing surface, i.e., at a location on the opposing surface where droplet accumulation is less likely. Therefore, it can collect liquid over a larger area of ​​the opposing surface, and the amount of droplets accumulating at the guide ribs is correspondingly increased. Consequently, the detection accuracy of liquid entry is improved.

[0039] Alternatively, in other embodiments of the battery module of this disclosure, a cylindrical second sleeve is wound around the connection between the second longitudinal extension and the signal line, the upper end of the second longitudinal extension is folded back downwards, and the second sleeve is adjacent to the other side of the second longitudinal extension in the width direction and extends downwards from the second longitudinal extension.

[0040] Based on the above structure, the second sleeve extends vertically. The downward flow of droplets along the opposite surface is less likely to be obstructed by the second sleeve. This ensures the amount of droplets collected at the guide ribs, improving the detection accuracy of liquid entry.

[0041] Alternatively, in other embodiments of the battery module disclosed herein, the vertical wall portion is a separate component from the battery assembly, located between the fan and the battery assembly.

[0042] Based on the above structure, since the vertical wall is a separate component from the battery assembly, it is easy to optimize the shape of the vertical wall and the configuration of the leakage sensor for the purpose of liquid accumulation. Therefore, the detection accuracy of liquid ingress is improved.

[0043] Hereinafter, specific examples of this disclosure will be described in detail based on the accompanying drawings. Furthermore, in the following description, terms indicating specific directions or positions (e.g., "upper," "lower," and other terms including these) will be used as needed, but these terms are used to facilitate understanding of this disclosure with reference to the accompanying drawings and are not intended to limit the technical scope of this disclosure by their meaning. Additionally, the same reference numerals appearing in multiple drawings indicate the same or equivalent parts or components. Moreover, the embodiments shown below represent specific examples of the technical concept of this disclosure and are not intended to limit this disclosure to the following. Furthermore, the dimensions, materials, shapes, and relative arrangements of the constituent components described below are not intended to limit the scope of this disclosure unless specifically stated, but are merely illustrative. Furthermore, the content described in one embodiment or example can be applied to other embodiments or examples. Additionally, there are cases where the size, positional relationships, etc., of the components shown in the drawings are exaggerated for clarity.

[0044] The battery module disclosed herein can be used, for example, as an emergency power source in a battery backup unit (BBU). However, this disclosure does not limit the intended use of the battery module; it can be used as a power source for various other electrical devices, such as a power source for a vehicle's drive motor.

[0045] Reference Figures 1-4 The battery module 1 of the first embodiment includes an outer casing 2, a battery assembly 3, a fan 5, a vertical wall 6, and a leakage sensor 7. The battery module 1 also includes a circuit unit 4.

[0046] The outer casing 2 is cuboid in shape, appearing rectangular when viewed along its height direction Z (i.e., when viewed from above). In the following description, the extension direction of the long side of this rectangle is defined as the length direction X, and the extension direction of the short side of this rectangle is defined as the width direction Y. The length direction X is orthogonal to both the width direction Y and the height direction Z, the width direction Y is orthogonal to both the length direction X and the height direction Z, and the height direction Z is orthogonal to both the length direction X and the width direction Y.

[0047] The outer housing 2 has a first end wall 21 and a second end wall 22 opposite each other in the longitudinal direction X, a bottom wall 23 and a top wall 24 opposite each other in the height direction Z, and a first side wall 25 and a second side wall 26 opposite each other in the width direction Y. The outer housing 2 defines an internal space surrounded by these walls. The first end wall 21 is located on one side in the longitudinal direction X ( Figure 1 , Figure 3 as well as Figure 4 The lower left side Figure 2 The second end wall 22 extends upward from the end of the bottom wall 23 (on the left side) and connects to the end of the top wall 24. The second end wall 22 is on the other side of the length direction X (…). Figure 1 as well as Figure 3 The upper right side) connects the ends of the bottom wall 23 and the top wall 24 to each other. The first side wall 25 is located on one side in the width direction Y ( Figure 1 as well as Figure 3 The first end wall 21 and the second end wall 22 are connected on the upper left side. The second side wall 26 is on the other side in the width direction Y ( Figure 1 as well as Figure 3 (on the lower right side) connect the first end wall 21 and the second end wall 22.

[0048] The outer housing 2 has an inlet 27 located on the first end wall 21 and an outlet 28 located on the second end wall 22. Both the inlet 27 and the outlet 28 are composed of multiple through holes, which connect the interior and exterior of the outer housing 2 and allow air-cooled air to pass through the electrical components inside the outer housing 2.

[0049] The outer housing 2 has a base 2A and a cover 2B that can be separated in the height direction Z as its constituent components. The base 2A forms at least a bottom wall 23, and in this example, also forms a first side wall 25 and a second side wall 26. The cover 2B forms at least a top wall 24. In this embodiment, the outer housing 2 also has an end plate 2C that forms a first end wall 21 as its constituent component. However, the component division of the outer housing 2 can be appropriately modified. The second end wall 22 can be integrated with the base 2A, integrated with the cover 2B, or it can be composed of a component that is separate from the base 2A and the cover 2B.

[0050] The fan 5, leakage sensor 7, vertical wall 6, battery assembly 3, and circuit unit 4 are housed inside the outer casing 2 in the order described above, from one side of the length direction X toward the other.

[0051] The battery assembly 3 includes multiple battery cells (not shown) and a cell holder 31 that holds the multiple battery cells in a fixed position. For example, the battery cells are non-aqueous electrolyte secondary batteries such as lithium-ion batteries, and have a cylindrical container. However, the battery cells can also be batteries other than cylindrical batteries, such as square ones, or batteries other than lithium-ion batteries, such as all-solid-state batteries.

[0052] The cell holder 31 is generally rectangular in shape. Although detailed drawings are omitted, multiple battery cells are held in a longitudinally positioned posture with their axial direction towards the height direction Z. The cell holder 31 has multiple storage portions for individually accommodating the multiple battery cells. Each storage portion is cylindrical for accommodating the corresponding battery cell. When viewed from above, multiple storage portions are exposed on the two end faces in the length direction X and the two side faces in the width direction Y of the cell holder 31, forming the outline of the battery cell arrangement area. In this case, the surface of the cell holder 31 has unevenness due to the outer peripheral surfaces of these storage portions.

[0053] Furthermore, the battery assembly 3 may include a current-collecting structure and a heat-transfer structure (not shown). The current-collecting structure may include a lead plate made of a conductive material to electrically connect the battery cells to each other. The heat-transfer structure may include a sheet or plate made of a thermally conductive material to absorb heat from the battery cells. The above structures overlap with the top or bottom surface of the cell holder 31.

[0054] Circuit unit 4 may include a monitoring module for monitoring the state of individual battery cells, a charge / discharge control module for controlling the charging and discharging of individual battery cells, a voltage conversion module for converting DC voltage from or to individual battery cells (e.g., buck, boost, or both), and a fan control module for controlling the airflow of fan 5 based on the state of individual battery cells (e.g., temperature). Alternatively, a portion of the modules illustrated herein may be mounted independently of circuit unit 4 on substrate 49, which is disposed in other locations (e.g., the space between battery assembly 3 and the first end wall 21, or the space between battery assembly 3 and the first side wall 25 or the second side wall 26). When leakage sensor 7 detects liquid ingress, the charge / discharge control module and the voltage conversion module cease some or all of their functions.

[0055] As an example, fan 5 consists of a first fan 5A and a second fan 5B arranged in the width direction Y. The first fan 5A is, for example, an axial fan. The first fan 5A has: a fan frame 51, which is a rounded square shape when viewed axially; four bolt holes 52 located at the four corners of the fan frame 51; and an impeller (details omitted), which is rotatably supported at the center of the fan frame 51. When the impeller rotates, the first fan 5A draws in air from the rear and blows air out towards the front. The second fan 5B is constructed similarly to the first fan 5A.

[0056] Fan 5 is mounted on the inner surface of the first end wall 21. More specifically, the rear surface (suction-side end face) of the first fan 5A faces the inner surface of the first end wall 21 such that it covers the inlet 27. Four bolts 11 are inserted into the first end wall 21 from the outer surface side toward the other side in the longitudinal direction X, through four bolt through holes 52, and engaged with nuts 12 located on the front surface (discharge-side end face) of the fan 5. The second fan 5B is also fastened to the first end wall 21 in the same manner. The first fan 5A and the second fan 5B are arranged adjacent to each other in the width direction Y, and cover the first end wall 21, particularly its upper half, from the inside.

[0057] Fan 5 generates an airflow along its axial direction. The axial direction of fan 5 corresponds to the longitudinal direction X of battery module 1. The upstream side of the airflow direction corresponds to one side of the longitudinal direction X, and the downstream side of the airflow direction corresponds to the other side of the longitudinal direction X. Air is immediately drawn into fan 5 after passing through inlet 27 and blown out of fan 5 into the interior of outer casing 2. As the air flows into the interior of outer casing 2 towards the other side of the longitudinal direction X, it cools battery assembly 3 and circuit unit 4. Air flows out of outer casing 2 through outlet 28.

[0058] Here, there exists a situation where the outer surface of the outer casing 2 becomes wetted by liquid during the use of the battery module 1. For example, there may be cases where one or more battery modules 1 are arranged on a shelf together with external electronic devices to function as a BBU, and water cooling is used to cool these electronic devices. If a coolant leak occurs in the water cooling system, the coolant may drip onto the outer surface of the top wall 24 of the outer casing 2. Furthermore, examples of coolants (i.e., liquids that can adhere to the outer casing 2) include pure water, aqueous solutions of ethylene glycol, or aqueous solutions of propylene glycol.

[0059] Under the action of the fan 5, liquid (e.g., water) that wets the outer surface of the outer casing 2 is introduced toward the first end wall 21 and can enter the interior of the outer casing 2 through the inlet 27. The entering liquid passes through the inlet 27, the rear surface of the fan and the fan frame 51 in sequence, and is blown out from the front surface of the fan with the airflow.

[0060] The leak sensor 7 is, for example, a cable or rope type. The leak sensor 7 has a long, flexible, linear, rope-like, or strip-like detection cable 70. When liquid (e.g., water) comes into contact with the detection cable 70, the liquid permeates the cable 70, and the two electrode wires (not shown) within the cable 70 short-circuit due to the liquid. The leak sensor 7 detects this short circuit electrically, thereby detecting the presence of liquid in its surroundings. When the leak sensor 7 is housed inside the outer casing 2, where liquid is not normally present, the detection of the presence of liquid refers to the detection of liquid entering the outer casing 2.

[0061] The rear surface of the fan 5 contacts the inner surface of the first end wall 21, or faces the inner surface of the first end wall 21 through a small gap. This compresses the space behind the fan, which helps to increase the volumetric energy density of the battery module 1. On the other hand, when the gap between the rear surface of the fan and the first end wall 21 is blocked, there is no room to place the leak sensor 7 in the liquid inlet path (e.g., between the inlet 27 and the rear surface of the fan). In order for the leak sensor 7 to detect liquid inlet, it is required that the leak sensor 7 be placed in front of the fan inside the outer housing 2, and that as much liquid blown out with the airflow as possible comes into contact with the leak sensor 7.

[0062] The particle size of the liquid blown out by fan 5 may vary depending on the amount of liquid entering (especially the inflow rate per unit time). If the amount of liquid entering is small, the particle size is smaller, and the liquid is dispersed from fan 5 in a mist-like manner. Therefore, the actual amount of liquid adhering to leak sensor 7 is further reduced relative to the already small amount of liquid entering. Even if a portion of the mist is blown directly to leak sensor 7, the amount of liquid adhering per unit area is extremely small. Sufficient short circuits cannot occur at any point on the detection cable 70, making liquid entry detection difficult.

[0063] Therefore, the battery module 1 has a vertical wall portion 6 to maintain or improve the detection accuracy of liquid ingress even when the leakage sensor 7 is positioned in front of the fan. Furthermore, in this embodiment, the vertical wall portion 6 is composed of a component that is separate from the battery assembly 3, and more specifically, separate from the cell holder 31.

[0064] The following is for reference Figures 5-7 The structure and configuration of the vertical wall section 6 and the leakage sensor 7 are further explained.

[0065] The vertical wall portion 6 has a base plate 60 extending along the width direction Y and the height direction Z. One of the two surfaces of the base plate 60, along the length direction X, is... Figure 5 The lower left side Figure 6The surface on the lower right side of the fan 5 is the opposing surface 61, which is opposite to the fan 5 in the longitudinal direction X (in other words, the airflow direction, the fan axis). The opposing surface 61 is a flat surface. The normal of the opposing surface 61 is directed towards the longitudinal direction X.

[0066] The base plate 60 includes a central portion 60c in the width direction Y, and a side portion extending from the central portion 60c toward the width direction Y. Figure 5 upper left side Figure 6 The lower left side Figure 7 The first protruding portion 60a protruding from the left side, and the other side from the central portion 60c in the width direction Y ( Figure 5 The lower right side Figure 6 upper right side Figure 7 The second protrusion 60b protrudes from the right side.

[0067] The central portion 60c protrudes downward relative to the first protrusion 60a and the second protrusion 60b. The lower edges of the first protrusion 60a and the second protrusion 60b extend in a straight line along the width direction Y. The lower edge of the second protrusion 60b is located slightly above the lower edge of the first protrusion 60a.

[0068] A through hole 60d is provided in the central portion 60c. As an example, the through hole 60d is rectangular in shape, with a pair of long edges separated from each other in the width direction Y and extending parallel to the height direction Z, and a pair of short edges separated from each other in the height direction Z and extending parallel to the width direction Y. Alternatively, electronic components such as fuses can be disposed in the through hole 60d.

[0069] Furthermore, a through hole 60e is also provided in the first protrusion 60a. Additionally, the vertical wall portion 6 integrally has two edges extending from the base plate 60 in the width direction Y to the other side in the length direction X. Figure 5 upper right side Figure 6 The sidewall 69 protrudes from the upper left side. The through hole 60e is a shape provided for forming the sidewall 69. The sidewall 69 is used, for example, for fixing to the unit retainer 31 by means of snap-fit ​​assembly.

[0070] The vertical wall portion 6 has guide ribs 62 protruding from the lower part of the opposing surface 61 toward the fan 5. The guide ribs 62 mainly serve to guide and collect droplets adhering to the opposing surface 61.

[0071] The guide rib 62 has a curved rib 62a that bends toward the center side of the width direction Y of the opposite surface 61 as it moves downward.

[0072] The curved rib 62a, when viewed along the length direction X, is a downwardly convex semicircle, having a lower end located at the center in the width direction Y, and a pair of upper ends located opposite each other in the width direction Y. The curved rib 62a is a shape formed by stretching the semicircle along the width direction Y. In other words, the height of the curved rib 62a (the distance in the height direction Z between the upper and lower ends) is shorter than the width of the curved rib 62a (the distance in the width direction Y between the pair of upper ends).

[0073] The curved rib 62a protrudes from the edge of the lower protruding portion of the central portion 60c of the base plate 60 in the length direction X. As described above, the lower protruding portion is the part that protrudes downward relative to the first protrusion 60a and the second protrusion 60b. The lower end of the curved rib 62a is located at the lower end of the entire vertical wall portion 6 and is located at the center of the width direction Y of the entire vertical wall portion 6.

[0074] In this embodiment, a notch 62b is provided at the lower end of the curved rib 62a. The curved rib 62a is composed of a pair of segmented ribs that are divided into two in the width direction Y via the notch 62b. When viewed along the length direction X, each segmented rib is formed by stretching a quarter arc along the width direction Y, and bends towards the center side of the width direction Y as it moves downward.

[0075] The guide rib 62 also has an inclined rib 62c that is inclined downward as it moves toward the center side in the width direction Y, and is continuous with the upper end of the curved rib 62a.

[0076] Furthermore, in this embodiment, one inclined rib 62c is continuous with the upper end of one side of the curved rib 62a in the width direction Y (i.e., the upper end of the dividing rib on one side of the width direction Y). The guide rib 62 terminates at the upper end of the other side of the curved rib 62a in the width direction Y, and terminates at the upper end of the inclined rib 62c on one side of the width direction Y.

[0077] An inclined rib 62c extends from the lower corner of the first protrusion 60a along the width direction Y towards the upper side. The inclined rib 62c is located at the lower end of the first protrusion 60a. The inclined rib 62c extends in a straight line. The upper end of the inclined rib 62c reaches near the edge or corner of the through hole 60e.

[0078] The leak sensor 7 extends along the opposite surface 61 of the vertical wall portion 6, and is at least partially disposed along the guide rib 62. The leak sensor 7 includes a flexible, elongated detection cable 70.

[0079] Although detailed illustrations are omitted, the detection cable 70 includes: two electrode wires, an inner braid surrounding each electrode wire from the outside, and an outer braid that gathers the two electrode wires, which are wound together by the inner braid, and surrounds them from the outside. Both the outer and inner braids are made of chemical fibers such as polyester or polyethylene, and when liquid adheres to the outer surface of the detection cable 70, the liquid can reach the electrode wires. When the liquid short-circuits the two electrode wires, the leakage sensor 7 detects the liquid based on the change in resistance between the electrode wires.

[0080] With the leakage sensor 7 assembled on the vertical wall portion 6, the detection cable 70 forms a U-shape when viewed along the length direction X, including a lateral extension 71, a first longitudinal extension 72, and a second longitudinal extension 73. The lateral extension 71 extends along the lower edge of the opposing surface 61 in the width direction Y. The first longitudinal extension 72 extends upward from one side of the lateral extension 71 in the width direction Y. The second longitudinal extension 73 extends upward from the other side of the lateral extension 71 in the width direction Y.

[0081] The two ends of the detection cable 70 are connected to signal lines 79a and 79b. Signal line 79a is electrically and mechanically connected to two electrode lines inside the detection cable 70 by soldering. Signal line 79b is connected in the same way.

[0082] The battery module 1 includes: a first sleeve 77 that protects the connection between the end of the first longitudinal extension 72 (i.e., one end of the detection cable 70) and the signal line 79a; and a second sleeve 78 that protects the connection between the end of the second longitudinal extension 73 (i.e., the other end of the detection cable 70) and the signal line 79b. Both the first sleeve 77 and the second sleeve 78 are cylindrical with a diameter larger than that of the detection cable 70 and are wound around their respective connection portions.

[0083] The lateral extension 71 is disposed along the inner surface of the curved rib 62a. The lateral extension 71 is a downwardly convex semicircle when viewed along the length direction X, mimicking the shape of the curved rib 62a.

[0084] The first longitudinal extension 72 extends vertically along the long edge of the through hole 60d near the boundary between the central portion 60c and the first protrusion 60a. The upper end of the first longitudinal extension 72 bends at a right angle near the upper edge of the opposing surface 61 toward the other side in the width direction Y.

[0085] The first sleeve 77 extends linearly from the end of the first longitudinal extension 72 toward the other side in the width direction Y, along the upper edge of the opposing surface 61 and the upper edge of the through hole 60d. The first sleeve 77 reaches the second protrusion 60b. After extending downward along the opposing surface 61 of the second protrusion 60b from the end of the first sleeve 77 on the other side in the width direction Y, the signal line 79a extends through the wiring groove 63 toward the other side in the length direction X. The wiring groove 63 is provided on the side wall 69 on the other side in the width direction Y.

[0086] The second longitudinal extension 73 extends vertically along the long edge of the through hole 60d near the boundary between the central portion 60c and the second protrusion 60b. The upper end of the second longitudinal extension 73 is folded back downwards in a hairpin shape. This folded-back portion is located directly below the first sleeve 77.

[0087] The second sleeve 78 is adjacent to the other side of the second longitudinal extension 73 in the width direction Y, and extends downward in a straight line from the end of the second longitudinal extension 73. The second sleeve 78 is disposed along the opposite side of the second protrusion 60b, with the lower end of the second sleeve 78 located below the lower edge of the second protrusion 60b. The signal line 79b extends from the lower end of the second sleeve 78 in the length direction X to the other side.

[0088] The vertical wall portion 6 also includes a sensor clamp 64, a sensor hook 65, and a sensor guide 66. The sensor clamp 64, sensor hook 65, and sensor guide 66, like the guide rib 62, protrude from the opposing surface 61 toward the fan 5. The sensor clamp 64, sensor hook 65, and sensor guide 66 primarily serve to hold the leakage sensor 7 in a fixed position along the opposing surface 61.

[0089] The sensor clamp 64 consists of a pair of locking tabs protruding from opposite surfaces 61, with claws protruding from the front ends of the pair of locking tabs in a manner that brings them closer together. The sensor clamp 64 includes a bottom clamp 64a, a first side clamp 64b, a second side clamp 64c, a first sleeve clamp 64d, and a second sleeve clamp 64e.

[0090] A bottom clamp 64a is positioned at the notch 62b and clamps the central portion of the transverse extension 71 in the width direction Y. A first side clamp 64b is positioned near the boundary between the central portion 60c and the first protrusion 60a and clamps the central portion of the first longitudinal extension 72 in the height direction Z. A second side clamp 64c is positioned near the boundary between the central portion 60c and the second protrusion 60b and clamps the root of the hairpin portion of the second longitudinal extension 73. A first sleeve clamp 64d is positioned between the upper edge of the through hole 60d and the upper edge of the opposing surface 61 and clamps the first sleeve 77. A second sleeve clamp 64e is positioned at the central portion of both the height direction Z and the width direction Y of the second protrusion 60b and clamps the second sleeve 78.

[0091] The sensor hook 65 consists of a locking piece protruding from the opposing surface 61. The sensor hook 65 is disposed on both sides of the bottom clamp 64a in the width direction Y, and locks the lateral extension 71 from above. The lateral extension 71 is constrained in its posture and position by passing through a narrow space between the sensor hook 65 and the curved rib 62a.

[0092] The sensor guide 66 is formed by a ridge or rib protruding from the opposing surface 61. The sensor guide 66 includes a first side guide 66a, a second side guide 66b, a third side guide 66c, a first top guide 66d, and a second top guide 66e.

[0093] The first side guide 66a extends along one edge of the through hole 60d in the width direction Y and along the height direction Z. The first longitudinal extension 72 is disposed along the first side guide 66a, thereby extending in the height direction Z and being held near the through hole 60d. The second side guide 66b extends along the other edge of the through hole 60d in the width direction Y and along the height direction Z. The second longitudinal extension 73 is disposed along the second side guide 66b, thereby extending in the height direction Z and being held near the through hole 60d.

[0094] The first top guide 66d and the second top guide 66e extend along the upper edge of the opposing surface 61 in the width direction Y. The first top guide 66d is disposed on one side of the width direction Y relative to the first sleeve clamp 64d, guiding the right-angle bend of the upper end of the first longitudinal extension 72. The second top guide 66e is provided at the second protrusion 60b, guiding the front end of the first sleeve 77 and the lower extension of the signal line 79a.

[0095] The third side guide 66c extends along the height direction Z from the center of the width direction Y of the second extension 60b. The upper part of the third side guide 66c guides the hairpin bend of the second longitudinal extension 73, and the lower part of the third side guide 66c guides the downward extension of the second sleeve 78.

[0096] Reference Figure 7 The shaft of the first fan 5A passes through the first extension 60a. The shaft of the second fan 5B passes through the second extension 60b. Liquid blown out from the first fan 5A is caught by the opposite surface 61 of the first extension 60a. Liquid blown out from the second fan 5B is caught by the opposite surface 61 of the second extension 60b.

[0097] When the liquid inflow rate (inflow rate per unit time) is high, the liquid becomes droplets of a certain size and is blown towards the opposite surface 61. When the airflow of the fan 5 is high, the droplets splash along the length direction X. Sufficient liquid is deposited on the first longitudinal extension 72 and the second longitudinal extension 73 to short-circuit the electrode wires within the detection cable 70. Therefore, when the liquid inflow rate is high, especially when the airflow of the fan 5 is high, the liquid inflow can be detected early and with high accuracy.

[0098] When the amount of liquid entering is large and the airflow of fan 5 is small, the droplets fall and splash along the length direction X. Therefore, the droplets are caught by the lower parts of the first protrusion 60a and the second protrusion 60b. The liquid caught by the opposing surface 61 becomes droplets on the opposing surface 61. The droplets are drawn into the droplets attached to the opposing surface 61 below, and flow downward along the opposing surface 61 due to their own weight.

[0099] In this embodiment, the vertical wall portion 6 is composed of a separate component that separates from the battery assembly 3. Therefore, the opposing surface 61 can be easily formed flat. Compared to a case where the opposing surface 61 has unevenness, it is easier to control the direction of droplet flow.

[0100] The droplets adhering to the opposite surface 61 of the first protrusion 60a reach the inner surface of the inclined rib 62c. The front end of the inclined rib 62c is close to the edge or corner of the through hole 60e, thus the inclined rib 62c can capture approximately the entire amount of droplets adhering to the first protrusion 60a. The droplets are guided downwards and towards the center of the width direction Y along the inclination of the inclined rib 62c, reaching the inner surface of the curved rib 62a. The curved rib 62a is semi-circular, and the tangent at the junction of the curved rib 62a and the inclined rib 62c is approximately vertically downwards. Upon reaching the curved rib 62a, the droplets rapidly flow downwards. At the lower part of the curved rib 62a, the droplets rapidly flow towards the center of the width direction Y through the conversion of potential energy to kinetic energy. Thus, the droplets adhering to the first protrusion 60a accumulate at the lower end of the curved rib 62a.

[0101] At the lower end of the curved rib 62a, the central portion of the transverse extension 71 in the width direction Y is held by the bottom clamp 64a and the sensor hook 65. Droplets collected at the lower end of the curved rib 62a permeate the central portion of the transverse extension 71 in the width direction Y. Through the liquid accumulation effect based on the guide rib 62, a sufficient amount of liquid to short-circuit the electrode wires adheres to the transverse extension 71. Therefore, even with a low airflow from the fan 5, liquid ingress can be detected with high accuracy.

[0102] The same applies when the liquid inflow is small. With a small liquid inflow, the liquid particle size decreases, and the liquid becomes a mist. The misty liquid can directly adhere to the first longitudinal extension 72 and the second longitudinal extension 73, but it may not be sufficient to short-circuit the electrode wires. However, the opposing surface 61 can also receive the misty liquid. The received liquid forms droplets in the same manner as described above. The subsequent droplet movement is also the same as described above. The liquid gathers at the lower end of the curved rib 62a, and sufficient liquid to short-circuit the electrode wires can adhere to the transverse extension 71. Therefore, compared to the case where the liquid inflow is large and the airflow of the fan 5 is large, detection may take longer, but even with a small liquid inflow, liquid inflow can be detected with high accuracy.

[0103] Next, refer to Figures 8-10 The battery module 1 of the second embodiment will be described with a focus on the differences from the first embodiment.

[0104] In this embodiment, the curved rib 62a and notch 62b of the first embodiment are omitted (see reference). Figures 5-7 With the omission of the curved rib 62a, the lower protrusion of the central portion 60c of the base plate 60 becomes rectangular in shape when viewed along the length direction X. In addition, instead of omitting the curved rib 62a, the guide rib 62 has a first longitudinal rib 62d that is separated in the width direction Y and extends in the height direction Z and a second longitudinal rib 62e.

[0105] The first longitudinal rib 62d protrudes from the side of the lower part of the central portion 60c of the base plate 60 in the width direction Y. Figure 8 upper left side Figure 9 The lower left side Figure 10 The edge on the left side of the length direction X is on one side. Figure 8 The lower left side Figure 9 The second longitudinal rib 62e protrudes from the lower right side of the protrusion below the center portion 60c of the base plate 60 (in the width direction Y). Figure 8 The lower right side Figure 9 upper right side Figure 10The right edge of the yoke (the yoke) protrudes to one side in the length direction X.

[0106] In the first embodiment (refer to) Figures 5-7 In this embodiment, the lateral extension 71 is arranged along the curved rib 62a. In this embodiment, with the curved rib 62a omitted, the lateral extension 71 extends linearly in the width direction Y along the lower edge of the central portion 60c. Instead, the lower ends of the first longitudinal extension 72 and the second longitudinal extension 73 reach the lower end of the central portion 60c and are continuous with the lateral extension 71. The first longitudinal extension 72 is arranged along the inner surface of the first longitudinal rib 62d. The second longitudinal extension 73 is arranged along the inner surface of the second longitudinal rib 62e.

[0107] In this embodiment, the battery module 1 has an elastic support 67 instead of the bottom clamp 64a in the first embodiment (see reference). Figures 5-7 An elastic support 67 is located at the lower end of the central portion 60c, elastically supporting the lateral extension 71 from above. A pair of sensor hooks 65 also include a downwardly extending tab extending from the front end of the locking tab. The lateral extension 71 is held within the space surrounded by the locking tab and the downwardly extending tab of the sensor hooks 65.

[0108] In this embodiment, with the omission of the curved rib 62a, the lower end of the inclined rib 62c is continuous with the upper end of the first longitudinal rib 62d.

[0109] In this embodiment, the first side clamps are arranged in pairs, one above the other, and the second side clamps are arranged in pairs, one above the other. The sensor clamp 64 includes an upper first side clamp 64p, a lower first side clamp 64q, an upper second side clamp 64r, and a lower second side clamp 64s.

[0110] The upper first side clamp 64p clamps the root of the right-angle bend of the first longitudinal extension 72. The upper second side clamp 64r is configured and constructed in the same way as the second side clamp 64c in the first embodiment, and clamps the root of the hairpin portion of the second longitudinal extension 73.

[0111] The lower first side clamp 64q and the lower second side clamp 64s are provided on the lower protrusion of the central portion 60c. The lower first side clamp 64q clamps the lower end of the first longitudinal extension 72. The lower second side clamp 64s clamps the lower end of the second longitudinal extension 73.

[0112] The lower first side clamp 64q is positioned slightly towards the center of the width direction Y relative to the upper first side clamp 64p. Therefore, the first longitudinal extension 72 extends in a manner that gently traces the letter S at its lower end. The first longitudinal extension 72 bulges outward in the width direction Y at its continuation with the transverse extension 71 (i.e., the lower end of the first longitudinal extension 72) and contacts or approaches the inner surface of the first longitudinal rib 62d. Furthermore, the lower end of the first longitudinal rib 62d slopes downwards towards the center of the width direction Y. This slope also helps to shorten the distance between the inner surface of the first longitudinal rib 62d and the detection cable 70.

[0113] The relationship between the lower second side clamp 64s and the upper second side clamp 64r is the same as described above. The second longitudinal extension 73 extends in a manner that gently depicts the letter S at its lower end. The lower end of the second longitudinal rib 62e slopes downwards towards the center of the width direction Y. The lower end of the second longitudinal extension 73 contacts or approaches the inner surface of the second longitudinal rib 62e.

[0114] In this embodiment, when liquid is blown toward the opposing surface 61, it forms droplets on the opposing surface 61. The droplets fall downwards along the opposing surface 61. The droplets are guided by the guide ribs 62 and flow downwards along the lower surface of the first longitudinal rib 62d or the second longitudinal rib 62e. When the droplets reach the lower ends of the first longitudinal rib 62d and the second longitudinal rib 62e, they adhere to the detection cable 70. Thus, the leakage sensor 7 can detect the liquid ingress with high accuracy.

[0115] The implementation method has been described so far, but the above structure is only one example and can be appropriately modified within the scope of this disclosure.

[0116] Alternatively, a pair of inclined ribs 62c may be continuous with a pair of ends of a pair of curved ribs 62a (refer to the first embodiment) or the upper ends of a pair of longitudinal ribs 62d, 62e (refer to the second embodiment).

[0117] Alternatively, the vertical wall portion 6 may not be a dedicated component. For example, the vertical wall portion 6 may be integrated with the single retainer 31.

[0118] This disclosure may include the following methods.

[0119] (Method 1)

[0120] A battery module comprising:

[0121] External housing;

[0122] The battery assembly is housed within the outer casing;

[0123] The inlet is located on the end wall of the outer casing;

[0124] A fan, which is mounted on the inner surface of the end wall, blows air drawn in through the inlet into the interior of the outer housing;

[0125] A vertical wall portion having an opposing surface opposite to the fan, and guide ribs protruding from the lower part of the opposing surface toward the fan; and

[0126] A leak sensor extends along the opposite surface and is configured at least partially along the guide rib.

[0127] (Method 2)

[0128] In the battery module described in Method 1,

[0129] The leakage sensor includes a lateral extension that extends in the width direction along the lower edge of the opposite surface.

[0130] (Method 3)

[0131] In the battery module described in Method 2,

[0132] The guide rib has a curved rib that bends toward the center side of the width direction of the opposite surface as it moves downwards.

[0133] The lateral extension is configured along the inner surface of the curved rib.

[0134] (Method 4)

[0135] In the battery module described in method 3,

[0136] The guide rib has an inclined rib that is inclined downward as it moves toward the center in the width direction and is continuous with the upper end of the curved rib.

[0137] (Method 5)

[0138] In the battery module described in any of methods 2 to 4,

[0139] The leakage sensor includes: a first longitudinal extension extending upward from one end of the transverse extension in the width direction; and a second longitudinal extension extending upward from the other end of the transverse extension in the width direction.

[0140] (Method 6)

[0141] In the battery module described in method 5,

[0142] The guide rib has a first longitudinal rib and a second longitudinal rib that are separated from each other in the width direction and extend in the vertical direction.

[0143] The first longitudinal extension is disposed along the inner surface of the first longitudinal rib, and the second longitudinal extension is disposed along the inner surface of the second longitudinal rib.

[0144] (Method 7)

[0145] In the battery module described in method 5 or method 6,

[0146] A cylindrical first sleeve is wound around the connection between the first longitudinal extension and the signal line.

[0147] The upper end of the first longitudinal extension is bent toward the other side in the width direction, and the first sleeve extends from the first longitudinal extension toward the other side in the width direction along the upper edge of the opposite surface.

[0148] (Method 8)

[0149] In the battery module described in method 7,

[0150] A cylindrical second sleeve is wound around the connection between the second longitudinal extension and the signal line.

[0151] The upper end of the second longitudinal extension is folded back downwards, and the second sleeve is adjacent to the other side of the second longitudinal extension in the width direction and extends downwards from the second longitudinal extension.

[0152] (Method 9)

[0153] In any of the battery modules described in methods 1 to 8,

[0154] The vertical wall section is a separate component from the battery assembly, and it is located between the fan and the battery assembly.

[0155] Explanation of reference numerals in the attached figures

[0156] 1. Battery module; 2. Outer housing; 2A. Base; 2B. Cover; 2C. End plate; 3. Battery assembly; 4. Circuit unit; 5. Fan; 5A. First fan; 5B. Second fan; 6. Vertical wall; 7. Leakage sensor; 11. Bolt; 12. Nut; 21. First end wall; 22. Second end wall; 23. Bottom wall; 24. Top wall; 25. First side wall; 26. Second side wall; 27. Inlet; 28. Flow... Export; 31. Single unit retainer; 49. Base plate; 51. Fan frame; 52. Bolt through hole; 60. Base plate; 60a. First protrusion; 60b. Second protrusion; 60c. Central part; 60d. 60e. Through hole; 61. Opposing surface; 62. Guide rib; 62a. Bending rib; 62b. Notch; 62c. Inclined rib; 62d. First longitudinal rib; 62e. Second longitudinal rib; 63. Wiring groove; 64. 64a. Sensor clamp; 64b. First side clamp; 64c. Second side clamp; 64d. First sleeve clamp; 64e. Second sleeve clamp; 64p. Upper first side clamp; 64q. Lower first side clamp; 64r. Upper second side clamp; 64s. Lower second side clamp; 65. Sensor hook; 66. Sensor guide; 66a. First side guide; 66b. 66c, 66d, 66e, 66d, 66e, 66d, 66e, 66e, 66d, 67, 68, 69, 60, 61, 62, 63, 74, 75, 76, 76, 77, 78, 79 ...

Claims

1. A battery module, wherein, This battery module features: External housing; The battery assembly is housed within the outer casing; The inlet is located on the end wall of the outer casing; A fan, which is mounted on the inner surface of the end wall, blows air drawn in through the inlet into the interior of the outer housing; The vertical wall portion has an opposing surface opposite to the fan and a guide rib protruding from the lower part of the opposing surface toward the fan; as well as A leak sensor extends along the opposite surface and is configured at least partially along the guide rib.

2. The battery module according to claim 1, wherein, The leakage sensor includes a lateral extension that extends in the width direction along the lower edge of the opposite surface.

3. The battery module according to claim 2, wherein, The guide rib has a curved rib that bends toward the center side of the width direction of the opposite surface as it moves downwards. The lateral extension is configured along the inner surface of the curved rib.

4. The battery module according to claim 3, wherein, The guide rib has an inclined rib that is inclined downward as it moves toward the center in the width direction and is continuous with the upper end of the curved rib.

5. The battery module according to claim 2, wherein, The leakage sensor includes: a first longitudinal extension extending upward from one end of the transverse extension in the width direction; and a second longitudinal extension extending upward from the other end of the transverse extension in the width direction.

6. The battery module according to claim 5, wherein, The guide rib has a first longitudinal rib and a second longitudinal rib that are separated from each other in the width direction and extend in the vertical direction. The first longitudinal extension is disposed along the inner surface of the first longitudinal rib, and the second longitudinal extension is disposed along the inner surface of the second longitudinal rib.

7. The battery module according to claim 5, wherein, A cylindrical first sleeve is wound around the connection between the first longitudinal extension and the signal line. The upper end of the first longitudinal extension is bent toward the other side in the width direction, and the first sleeve extends from the first longitudinal extension toward the other side in the width direction along the upper edge of the opposite surface.

8. The battery module according to claim 7, wherein, A cylindrical second sleeve is wound around the connection between the second longitudinal extension and the signal line. The upper end of the second longitudinal extension is folded back downwards, and the second sleeve is adjacent to the other side of the second longitudinal extension in the width direction and extends downwards from the second longitudinal extension.

9. The battery module according to any one of claims 1 to 8, wherein, The vertical wall section is a separate component from the battery assembly, and it is located between the fan and the battery assembly.

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