Power supply device, power supply case for power supply device, and method for manufacturing power supply device

Abstract

This power supply device comprises a plurality of battery modules to which a plurality of secondary battery cells are connected, and a power supply case. The power supply case comprises: a case body having a first surface in which a plurality of insertion / removal ports for respectively accommodating the plurality of battery modules in an insertable / removable state are opened, and a second surface facing the first surface; and a plate portion that is fixed to a part of the case body and is configured as a separate member from the case body. The plate portion is provided with a stopper portion for regulating the push-in amount of the plurality of battery modules by interfering with end faces thereof when the battery modules are inserted from the end-face sides through the respective insertion / removal ports of the case body toward the second surface.

Description

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

[0001] The present disclosure relates to a power supply device, a power supply case for a power supply device, and a method for manufacturing a power supply device.

[0002] Battery modules, which are made up of multiple rechargeable secondary battery cells such as lithium-ion secondary batteries connected in series or parallel, are used in various fields as power supplies for driving target devices. For example, backup power supplies are used in which multiple battery modules, each made up of multiple secondary battery cells connected in series or parallel, are inserted into a rack.

[0003] A backup power supply unit for data centers consists of multiple battery modules, electrical components, and a power supply case. Each battery module is designed to be insertable and removable. The power supply unit also has an internal stopper to prevent interference between the battery modules and electrical components when inserting or removing a battery module.

[0004] These stoppers are used to position the battery modules when they are inserted into the rack. Specifically, when the battery module is pushed to a specified position, the stoppers abut against the end face of the battery module to prevent it from being pushed further. This holds the battery module in place. In this state, the battery-side connector on the end face of the battery module is mated with the case-side connector mounted on the circuit board located at the back of the power supply case, electrically connecting the battery module to the circuit board of the power supply case.

[0005] U.S. Patent Application Specification US2019 / 0273366A U.S. Patent Application Specification US2018 / 0063988A

[0006] There is a demand for higher capacity and higher output from battery modules that make up power supply devices. However, when battery modules are made longer to accommodate more secondary battery cells, it is necessary to redesign the power supply case so that the position of the stopper part can be changed accordingly. In particular, the position of the stopper part, which determines the insertion margin of the battery module, varies depending on the longitudinal length of the battery module, which creates the problem that the design of the power supply case cannot be standardized for battery modules with different longitudinal lengths.

[0007] One object of the present disclosure is to provide a power supply device that can accommodate variations in the longitudinal length of battery modules. Another object is to provide a power supply device that can use a common power supply case even when battery modules have different lengths. Note that the description of these objects and objects of the present disclosure does not preclude the existence of other objects and objects. Furthermore, it is not necessary for one embodiment of the present disclosure to solve all of these objects. Furthermore, other objects can be extracted from the description of the specification, drawings, and claims of the present disclosure.

[0008] According to one aspect of the present disclosure, there is provided a power supply device including a plurality of battery modules, each having a plurality of secondary battery cells, and a power supply case that houses the plurality of battery modules. The power supply case includes a case body having a first surface with a plurality of insertion / removal openings through which the plurality of battery modules are inserted and removed, and a second surface opposite the first surface, and a plate portion that is fixed to a portion of the case body and is made of a separate member from the case body. The plate portion has stopper portions that interfere with the end faces of the plurality of battery modules when the plurality of battery modules are inserted from the respective end faces of the plurality of insertion / removal openings of the case body toward the second surface.

[0009] Another aspect of the present disclosure provides a power supply case for a power supply device for storing a plurality of battery modules, each having a plurality of secondary battery cells connected thereto, the power supply case including: a case body having a first surface with a plurality of insertion / removal openings for insertably and removably storing the plurality of battery modules, and a second surface opposite the first surface; and a plate portion fixed to a portion of the case body and formed as a separate member from the case body. The plate portion has stopper portions that interfere with end faces of the battery modules when the plurality of battery modules are inserted from each end face side through the insertion / removal openings of the case body toward the second surface side, thereby regulating the amount of insertion.

[0010] Furthermore, according to one embodiment of the present disclosure, there is provided a method for manufacturing a power supply device including a plurality of battery modules, each having a plurality of secondary battery cells, and a power supply case housing the plurality of battery modules. The power supply case includes a case body having a first surface with a plurality of insertion / removal openings for insertably and removably housing the plurality of battery modules, and a second surface opposite the first surface, and a plate portion secured to a portion of the case body and formed as a separate member from the case body. The manufacturing method includes the steps of: preparing the plate portion with stopper portions that interfere with end faces of the battery modules to limit the amount of insertion when the plurality of battery modules are inserted from each end face of the battery modules through the insertion / removal openings of the case body toward the second surface; and securing the plate portion to a portion of the case body.

[0011] According to one embodiment of the power supply device, power supply case for the power supply device, and method for manufacturing the power supply device of the present disclosure, by configuring the plate portion with the stopper portion as a separate member from the case body, even if the length of the battery module to be inserted is changed, it can be accommodated by simply replacing the plate portion with the position of the stopper portion changed accordingly, thereby avoiding the need to redesign the case body.

[0012] FIG. 1 is an exploded perspective view showing the insertion and removal of a battery module into a power supply device according to a first embodiment. FIG. 2 is an exploded perspective view of the power supply device of FIG. 1, as seen from the rear side. FIG. 3 is an exploded perspective view of a power supply case of the power supply device of FIG. 1. FIG. 4 is an exploded perspective view of the power supply case of FIG. 3, as seen from the rear side. FIG. 5 is an exploded perspective view of the power supply case of FIG. 4, with the circuit board and insulating sheet removed. FIG. 6 is an enlarged perspective view of the power supply case of FIG. 5. FIG. 7 is an exploded perspective view of the power supply case of FIG. 5, with the plate portion removed. FIG. 8 is a vertical cross-sectional view of the power supply device of FIG. 1, taken along line VIII-VIII. FIG. 9 is an exploded perspective view of the battery module of FIG. 1. FIG. 10 is a schematic cross-sectional view of the power supply device according to the first embodiment. FIG. 11 is a schematic cross-sectional view showing battery modules of different lengths inserted into the case body of FIG. 10. FIG. 12 is an exploded perspective view of a power supply device according to a comparative example, as seen from the rear side. FIG. 13 is an enlarged perspective view of a stopper portion of the power supply device according to the comparative example. FIG. 14 is a schematic cross-sectional view showing the insertion of a battery module into the power supply case of the power supply device according to the comparative example. Fig. 15 is a schematic cross-sectional view showing a state in which the battery module has been elongated in the power supply device of Fig. 14. Fig. 16 is a schematic cross-sectional view showing a power supply device according to a modified example. Fig. 17 is a perspective view of a plate portion. Fig. 18 is a perspective view of a plate portion of a power supply device according to embodiment 2. Fig. 19 is a perspective view of a plate portion of a power supply device according to embodiment 3.

[0013] The embodiments of the present disclosure may be specified by the following configurations and features.

[0014] In a power supply device according to another aspect of the present disclosure, in the above-described aspect, the case body defines a plurality of storage spaces therein, each of which communicates with the plurality of insertion / removal openings and which respectively houses the plurality of battery modules.

[0015] In addition, in the power supply device according to another aspect of the present disclosure, in any of the above aspects, the end faces of the plate portions are not exposed above the bottom surface of each storage space, which makes it possible to avoid a situation in which the end faces of the plate portions interfere with and hinder the insertion of the battery module into the power supply case.

[0016] In addition, in the power supply device according to another aspect of the present disclosure, in any of the above aspects, the inner surface of the case body is configured so that the mounting surface of the case body on which the plurality of battery modules are mounted and the upper surface of the plate portion are flush with each other. With this configuration, even though the plate portion is added to the case body, the addition of the plate portion does not cause a change in height, and it is possible to avoid interference of the plate portion when pushing in the battery modules.

[0017] Furthermore, in another form of the power supply device of the present disclosure, in any of the above forms, the case main body forms a bottom opening by opening a portion of its bottom surface, and the plate portion is arranged to close the bottom opening.

[0018] In still another aspect of the power supply device of the present disclosure, in any of the above aspects, the power supply device further includes a circuit board disposed inside the case body between the end faces of the plurality of battery modules and the second surface, and the plate portion is provided with a plate-side board fixing portion for fixing a portion of the circuit board. With the above configuration, even when the width of the circuit board is changed in accordance with a change in the length of the battery modules inserted into the power supply case, the position of the plate-side board fixing portion provided on the plate portion can be adjusted in accordance with the changed width of the circuit board, and circuit boards of different depths can be accommodated without redesigning the case body.

[0019] In a power supply device according to still another aspect of the present disclosure, in any of the above aspects, the case main body is provided with a case-side board fixing portion for fixing another portion of the circuit board. With this configuration, while the position of the case-side board fixing portion provided on the case main body is fixed, the position of the plate-side board fixing portion provided on the plate portion can be changed by replacing the plate portion, making it possible to fix circuit boards of different widths.

[0020] In a power supply device according to still another aspect of the present disclosure, in any of the above aspects, the circuit board is placed in the case body in a position that follows the insertion direction of the battery module. With this configuration, the circuit board can be held in a horizontal position between the battery module and the second surface of the case body.

[0021] In a power supply device according to still another aspect of the present disclosure, in any of the above aspects, the case body has the plurality of insertion / removal openings arranged side by side on the first surface, which allows the plurality of battery modules to be inserted into and removed from the power supply case in a side-by-side orientation.

[0022] Furthermore, in the power supply device according to another aspect of the present disclosure, in any one of the above aspects, the stopper portion is formed in a semicircular shape in cross section.

[0023] In yet another aspect of the power supply device of the present disclosure, in any of the above aspects, the power supply device is a backup power supply for a data center. With the above configuration, particularly in backup power supplies for data centers, the diameter size of the battery modules and the like is specified by standards, so that in order to increase the capacity by making the battery modules larger, it is only possible to extend them in the depth direction. However, changing the module length in the depth direction requires redesigning the power supply case itself, including the stopper portion. However, by providing the stopper portion in a plate portion that is a separate member, this can be addressed while keeping the case body common.

[0024] In yet another aspect of the present disclosure, in the method for manufacturing a power supply device according to any of the above aspects, the step of preparing the plate portion includes a step of determining a plate length D1 in the depth direction of the plate portion such that D1 > Lmax - Lmin, where Lmax is the maximum anticipated module length of the battery module and Lmin is the minimum anticipated module length of the battery module. This allows the position of the stopper portion to be changed within the range of the plate length of the plate portion, thereby making it possible to accommodate the entire range of anticipated module lengths of the battery module.

[0025] Embodiments of the present disclosure will be described below with reference to the drawings. However, the embodiments described below are merely examples for embodying the technical concepts of the present disclosure, and the present disclosure is not limited to the following. Furthermore, this specification does not in any way specify the components set forth in the claims to be those of the embodiments. The dimensions, materials, shapes, relative positions, etc. of components described in the embodiments are not intended to limit the scope of the present disclosure, and are merely illustrative examples, unless otherwise specified. The size and positional relationships of components shown in the drawings may be exaggerated for clarity. Furthermore, in the following description, the same names and symbols indicate components that are identical or of the same quality, and detailed descriptions will be omitted as appropriate. Furthermore, the elements constituting the present disclosure may be configured with the same components, such that multiple elements are shared by one component, or conversely, the functions of one component may be shared by multiple components.

[0026] The power supply device of the present disclosure can be used as a stationary power supply device, for example, a backup power supply for a data center, a power storage device for storing power generated by solar power generation or the like for home, business, or factory use, or a power supply for daytime peak shaving. Hereinafter, as one embodiment of the present disclosure, a power supply device used as a backup power supply for a data center will be described. Power supply devices for data centers are used by being inserted into a storage space such as a rack, in the same way as hardware such as servers, storage, and network switches. Such power supply devices mounted in a rack are also called power shelves.

[0027] First Embodiment A power supply device 100 according to a first embodiment of the present disclosure is shown in FIGS. 1 to 11. FIG. 7 is an exploded perspective view of the power supply case 10 of FIG. 5 with the circuit board 30 and the insulating sheet 34 removed from it; FIG. 8 is a vertical cross-sectional view of the power supply device 100 of FIG. 1 taken along line VIII-VIII; FIG. 9 is an exploded perspective view of the battery module 2 of FIG. 1; FIG. 10 is a schematic cross-sectional view of the power supply device 100 of embodiment 1; and FIG. 11 is a schematic cross-sectional view of battery modules 2′ of different lengths inserted into the case body 11 of FIG. 10. The power supply device 100 shown in these figures comprises a power supply case 10 and a battery module 2. A circuit board 30 is disposed on the rear side of the power supply case 10.

[0028] (Power supply case 10) The power supply case 10 is a component for housing one or more battery modules 2 in a removable insertable manner, and constitutes the exterior of the power supply device 100. The power supply case 10 is composed of a case body 11 having a box-like exterior, and has a first surface 12 and an opposing second surface 13. In the examples of Figures 1 and 2, etc., the front side of the case body 11 is the first surface 12, and the back side is the second surface 13. The first surface 12 has insertion / removal openings 14 for inserting and removing the battery modules 2. In the examples of Figures 1 and 2, etc., the exterior of the case body 11 of the power supply case 10 is flat, and the insertion / removal openings 14 are arranged horizontally on the first surface 12 on the front side, and multiple battery modules 2 are arranged side by side.

[0029] Specifically, as shown in the exploded perspective views of Figures 3 to 7, the case body 11 is divided into four parts: a first case body 15, a second case body 16, a third case body 17, and a fourth case body 18. The first case body 15 and the second case body 16 form a lid, and the first case body 15 and the second case body 16 close the top of the third case, which is bent in a U-shape to open the top. The second surface 13, which is the back surface of the case body 11, is closed by the fourth case body 18. Furthermore, multiple partition plates 19 are fixed parallel to each other and spaced apart inside the case body 11 to define multiple storage spaces 3. Each storage space 3 is connected to the insertion / removal opening 14 and houses a battery module 2. 3 to 7 show a state in which the plurality of partition plates 19 are fixed to the bottom surface of the third casing 17 for convenience of illustration, but it goes without saying that the plurality of partition plates 19 may be fixed to the first casing 15 instead of or in addition to the third casing 17. The second casing 16 is configured separately from the first casing 15 so as to facilitate access to the circuit board 30 and the plate portion 20 when the plurality of partition plates 19 are fixed to the first casing 15 or the third casing 17.

[0030] (Circuit Board 30) Furthermore, a circuit board 30 is disposed on the rear side of the case body 11, between the second surface 13 and the battery module 2. The circuit board 30 is placed inside the case body 11 in a position that is aligned with the insertion direction of the battery module 2. In other words, the circuit board 30 is held in a horizontal position between the battery module 2 and the second surface 13.

[0031] The circuit board 30 is mounted with electronic circuits such as a current detection circuit that detects charging and discharging currents, a circuit that detects and calculates the full charge and remaining capacity of the secondary battery cells based on battery information such as the voltage and temperature of the secondary battery cells input from the battery-side circuit boards of the battery blocks each having multiple interconnected secondary battery cells, a control circuit that controls the charging and discharging of the secondary battery cells, and a protection circuit that monitors whether the battery is normal. The circuit board 30 is formed in a rectangular shape. In the example shown in Figure 4, the circuit board 30 is fixed in a horizontal position on the back side of the power supply case 10. The circuit board 30 is preferably made of resin such as glass epoxy.

[0032] 5, an insulating sheet 34 may be interposed between the circuit board 30 and the case body 11. This improves the insulation on the back surface of the circuit board 30.

[0033] The power supply case is not limited to the above-described configuration, and the insertion / removal openings may be stacked vertically on the case body so that the housing units are arranged vertically. The housing units may also be arranged in a grid pattern. It is not necessary to insert housing units into all of the insertion / removal openings 14 of the power supply case 10; the number of housing units to be inserted into the power supply case may be determined depending on the output, capacity, etc. required for the power supply device. The shape and length of the opening edge of the insertion / removal opening are designed according to the size of the battery module to be inserted or removed. Furthermore, the case body 11 is preferably made of a metal such as sheet metal that has excellent heat dissipation properties.

[0034] (Battery Module 2) The battery module 2 is inserted into and removed from the insertion / removal opening 14 of the case body 11. The battery module 2 has an outer shape formed into a rod that extends in one direction to facilitate insertion and removal. The rod-shaped battery module 2 is preferably formed into a box shape. One end face of the box-shaped battery module 2 in the longitudinal direction DL serves as an insertion surface 41 through which each housing is inserted into the case body 11. The other end face serves as an exposed surface 42 that is exposed from the case body 11 when inserted into the case body 11. In the example shown in FIG. 1 etc., the battery module is formed into a prism shape with square end faces. However, the shape of the battery module is not limited to this, and the end faces may be rectangular, octagonal, or the like.

[0035] As shown in Fig. 9, each battery module 2 houses multiple secondary battery cells 1 in a box-shaped module housing 43. Each battery module 2 outputs an output, which is generated by connecting the multiple secondary battery cells 1 housed therein in series or parallel, to the power supply case 10. For this reason, the battery module 2 is provided with a battery-side connector 44 for connecting to the power supply case 10. The case body 11 is also provided with a case-side connector 32 that connects to the battery-side connector 44.

[0036] The battery-side connector 44 is provided on the insertion surface 41 side of the battery module 2. The case-side connector 32 is provided on the circuit board 30 in a position facing the insertion surface 41 of the battery module 2. The battery-side connector 44 and the case-side connector 32 are arranged so that when the battery module 2 is inserted into the case body 11 and the insertion surface 41 comes into contact with a stopper portion 21 (described later) and stops, the battery-side connector 44 engages with the case-side connector 32.

[0037] As shown in the exploded perspective view of FIG. 9 , the module housing 43 of the battery module 2 is formed in a box shape that extends in the front-to-rear direction, and provides an assembly storage space for the internal assembly 45 inside. This module housing 43 is composed of a first module case 43A that is U-shaped in cross section and has an open bottom, and a second module case 43B that closes the bottom of the first module case 43A. These first module case 43A and second module case 43B are formed into a predetermined shape by bending a metal plate, for example. Examples of such metal plates that can be used are hot-dip galvanized steel plate, aluminum, and aluminum alloy.

[0038] The assembly storage space inside the module housing 43 houses an internal assembly 45. The internal assembly 45 includes a battery block containing multiple rechargeable battery cells 1 and an output unit with output terminals. The battery block contains, for example, multiple cylindrical rechargeable battery cells 1 arranged vertically and parallel to one another in a battery holder. The battery holder is preferably made of a material with excellent insulating and heat-resistant properties, such as a resin such as polycarbonate or ABS. The multiple rechargeable battery cells 1 are connected in parallel and in series. The rechargeable battery cells 1 are lithium-ion rechargeable batteries. A battery module 2 using lithium-ion rechargeable batteries 1 can achieve high output per unit volume and weight. However, lithium polymer batteries and nickel-metal hydride batteries can also be used as the rechargeable battery cells instead of lithium-ion batteries. Therefore, the present disclosure does not limit the rechargeable battery cells to lithium-ion batteries; any rechargeable battery can be used as the rechargeable battery cells.

[0039] Furthermore, the battery block has a module substrate arranged vertically on the side of the battery holder, and lead plates 46 connected to the end electrodes of the rechargeable battery cells 1 are connected to the module housing 43 to detect the intermediate potential of the rechargeable battery cells 1 connected to each other in series. Furthermore, the module housing 43 is equipped with an electronic circuit that detects the state of the multiple rechargeable battery cells 1. This electronic circuit includes a voltage detection circuit that detects the total potential and intermediate potential of the battery assembly in which the rechargeable battery cells 1 are connected in series or in parallel, and a circuit that detects the temperature of the multiple rechargeable battery cells 1.

[0040] (Plate Member 20) As shown in Figures 5 to 7 and 10, the power supply case 10 also includes a plate member 20 that is fixed to a portion of the case body 11 and is constructed as a separate member from the case body 11. The plate member 20 is provided with stopper members 21 that interfere with or abut against the end faces (insertion faces 41) of the battery modules 2 when the battery modules 2 are inserted from each end face (insertion face 41) through the insertion openings 14 of the case body 11 toward the second face 13, thereby restricting the amount of insertion. By constructing the plate member 20 with the stopper members 21 as a separate member from the case body 11 in this way, even if the module length of the battery modules 2' to be inserted is changed from L1 in Figure 10 to L2 in Figure 11, this can be accommodated by preparing a plate member 20' with the stopper members 21' positioned accordingly, thereby avoiding the need to redesign the case body 11.

[0041] FIG. 12 is an exploded perspective view of a power supply device 600 for a data center according to a comparative example. As shown in this figure, the power supply device 600 for a data center is composed of a power supply case 610, a plurality of battery modules 602 that are inserted into and removed from the power supply case 610, and electrical components 630. The battery modules 602 are detachable and replaceable. In this power supply device 600, a stopper is provided on the power supply case 610 to prevent interference between the battery modules 602 and the electrical components 630 when the battery modules 602 are inserted or removed. The stopper is provided to position the insertion margin of the battery modules 602 and is also called a ring stopper or the like. In the power supply device 700 of FIG. 13, a pin-shaped stopper 721 is used.

[0042] As shown in the schematic cross-sectional view of FIG. 14 , this stopper portion 821 is used to position the battery module 802 when the battery module 802 is inserted into the power supply case 810. Specifically, when the battery module 802 is pushed to a specified position, the stopper portion 821 abuts against the end face of the battery module 802 to prevent the battery module 802 from being pushed in any further. This holds the battery module 802 in a fixed position. In this state, a battery-side connector 844 provided on the end face of the battery module 802 is fitted into a case-side connector 832 mounted on a circuit board 830 located at the back of the power supply case 810, and the battery module 802 is electrically connected to the circuit board 830 of the power supply case 810.

[0043] Such power supplies for data centers are inserted into storage spaces such as racks for use. Meanwhile, it is common for equipment used in data centers and other applications to use standardized hardware, including power supplies, such as servers, storage, and network switches. For example, six battery modules used for backup purposes are installed in a power supply unit located in the center of the rack. While there are multiple standards, a typical standard specifies the height of equipment mounted in a rack in units called OUs (open units). One OU is 1.89 inches (48 mm) and its width is 21 inches (533.4 mm).

[0044] In recent years, due to factors such as increased demand for generating AI, there has been a demand for higher capacity and higher output for the battery modules 2 that make up power supply devices. However, due to standard restrictions, it is not possible to increase the width of the battery modules. Therefore, it is necessary to enlarge the battery modules. In this case, to increase the size of the battery modules without changing the size of the rack in which the power supply device is installed, it is necessary to enlarge the battery modules in the depth direction of the power supply device, i.e., the longitudinal direction in which the battery modules are inserted. Therefore, it was necessary to reduce the size of the electrical components at the back of the storage space of the rack in which the power supply device is installed.

[0045] For example, consider a case where, in the power supply device 800 shown in FIG. 14 , a battery module 902 with a total length L2 longer than the module length L1 in FIG. 14 is installed in a power supply case 910, as in the power supply device 900 shown in FIG. 15 , in order to increase the capacity of the battery module 802. The length of the circuit board 930 constituting the electrical equipment section is correspondingly reduced from B1 to B2. In this case, because the length of the battery module 902 is longer than the battery module 802 in FIG. 14 , the position of the stopper 921 for positioning the battery module 902 in a fixed position within the power supply case 910 must be shifted to the left of the stopper 821 in FIG. 14 . As a result, although the external shape of the power supply case 910 in FIG. 15 is the same as that of the power supply case 810 in FIG. 14 , the position of the stopper is different inside, and so a new design was required. As such, the position of the stopper portion, which determines the insertion position of the battery module, varies depending on the longitudinal length of the battery module, so it was not possible to standardize the design of the power supply case for potential modules with different longitudinal lengths.

[0046] In contrast to this, in the power supply device 100 according to this embodiment, as shown in the exploded perspective view of FIG. 7 , a stopper portion 21 is provided on a plate portion 20 which is formed as a separate member from the case body 11. This means that even if the length of the battery module 2 to be inserted into the case body 11 is changed from L1 to L2, the case body 11 can be accommodated without being redesigned by simply replacing it with a plate portion 20 in which the position of the stopper portion 21 has been changed accordingly, and it becomes possible to standardize the case body 11 for a wide variety of battery modules 2, thereby reducing manufacturing costs.

[0047] In particular, in backup power supplies for data centers, the diameter size of battery modules, etc. is specified by standards, so in order to increase the capacity by making the battery module larger, it can only be extended in the depth direction. However, if the module length in the depth direction is changed, the power supply case itself, including the stopper portion, must be redesigned. However, by providing the stopper portion 21 on the plate portion 20, which is a separate member, this can be addressed while keeping the case body 11 common.

[0048] The position of the stopper portion 21 is determined based on the module length of the battery module 2. As shown in FIG. 10 , the stopper portion 21 is provided at a position L1 from the first surface 12 of the case body 11 based on the module length L1 of the battery module 2. On the other hand, when the battery module 2′ has a module length L2 as shown in FIG. 11 , the stopper portion 21′ is provided on the plate portion 20′ at a position L2 from the first surface 12. In this way, so that the position of the stopper portion 21 can be adjusted based on the module length of the battery module 2, the plate length D1 in the depth direction of the plate portion 20, i.e., the longitudinal direction DL along which the battery module 2 is inserted, is designed based on the expected module length of the battery module 2. Specifically, it is preferable to design the plate length so that D1 > (maximum expected module length Lmax of the battery module) - (minimum expected module length Lmin of the battery module).

[0049] The plate portion 20 is also provided with a plate-side board fixing portion 22 for fixing a portion of the circuit board 30. With this configuration, even when the width in the depth direction of the circuit board 30′, i.e., the board length, is changed in accordance with a change in the length of the battery module 2′ inserted into the case body 11 as shown in Fig. 11 , the position of the plate-side board fixing portion 22′ provided on the plate portion 20′ can be adjusted in accordance with the changed board length of the circuit board 30′, and the case body 11 can be accommodated for circuit boards 30 of different board lengths without having to be redesigned.

[0050] Meanwhile, the case body 11 is provided with a case-side board fixing portion 36 for fixing another portion of the circuit board 30. The circuit board 30 is fixed to the case body 11 and the plate portion 20 by the case-side board fixing portion 36 and the plate-side board fixing portion 22. In the examples shown in Figures 6 and 7, the case-side board fixing portion 36 and the plate-side board fixing portion 22 are each configured as a cylindrical spacer with a threaded groove cut on the inner surface, but the case-side board fixing portion 36 and the plate-side board fixing portion 22 are not limited to this, and any known configuration capable of fixing the circuit board 30 can be used as appropriate.

[0051] Furthermore, the fixing position of the case-side board fixing portion 36 is fixed near the second surface 13 of the case body 11, while the fixing position of the plate-side board fixing portion 22 is determined according to the board length of the circuit board 30. That is, since the board length may change depending on the module length as described above, changes in the board length of the circuit board 30 can be avoided by adjusting the plate-side board fixing portion 22 of the plate portion 20. Specifically, in the example of FIG. 10 , the position of the plate-side board fixing portion 22 on the plate portion 20 is designed according to the board length B1 of the circuit board 30 so that the plate-side board fixing portion 22 is located at approximately B1 from the second surface 13. In the example of FIG. 11 , the position of the plate-side board fixing portion 22 on the plate portion 20′ is designed according to the board length B2 of the circuit board 30′, which is shortened according to the module length L2, so that the plate-side board fixing portion 22′ is located at approximately B2 from the second surface 13. In this way, changes in the length of the board can be accommodated by changing the design of the plate portion 20, which contributes to standardization of the case body 11.

[0052] The plate portion 20 is fixed to the bottom surface 3B of each storage space 3 so that the end surface 120E of the plate portion 20 does not protrude above the bottom surface 3B. In other words, when viewed in the longitudinal direction DL, the plate portion 20 does not protrude in the upward direction Du from the bottom surface 3B of the storage space 3. When viewed in the longitudinal direction DL, the end surface 120E of the plate portion 20 does not protrude above the bottom surface 3B of each storage space 3. This configuration makes it possible to avoid a situation where the end surface 120E of the plate portion 20 gets caught and hinders insertion when inserting the battery module 2 into the power supply case 10.

[0053] Specifically, the plate portion 20 is fixed at a position that is continuous with the bottom surface 3B of each storage space 3. In other words, the placement surface on which the battery module 2 is placed in the storage space 3 defined on the inner surface of the case body 11 and the upper surface 120A of the plate portion 20 are formed to be flush with each other.

[0054] 7 and other examples, a bottom opening 24 is formed in a portion of the bottom surface of the case body 11. The plate portion 20 is arranged to close the bottom opening 24. This allows the plate portion 20 to be added to the case body 11 without causing a change in height due to the addition of the plate portion 20, and prevents the plate portion 20 from interfering when the battery module 2 is pushed in.

[0055] [Modification] As described above, the configuration for adding the plate portion 20 to the case body 11 and aligning the bottom surface 3B of the storage space 3 and the upper surface 120A of the plate portion 20 in the same plane is not limited to the configuration in which the bottom opening 24 is formed. As an example, in a power supply unit 100′ according to a modification shown in the schematic cross-sectional view of FIG. 16 , a recess 24′ is formed in a portion of the bottom surface of the case body 11, where the plate portion 20 is fixed. Even with this configuration, it is possible to align the upper surface 120A of the plate portion 20 with the bottom surface 3B of the storage space 3 and prevent the end surface 120E of the plate portion 20 from protruding. Furthermore, compared to a configuration in which an opening is provided in the case body 11, this configuration also offers the advantage of increasing the rigidity of the case body 11 by not providing an opening and by partially doubling the case body 11.

[0056] 1, 3, etc., the case body 11 has a first surface 12 on which a plurality of insertion / removal openings 14 are opened side by side. Also, as shown in FIGS. 5 to 7, etc., the plate portion 20 extends in a direction intersecting the storage spaces 3 so as to cross the storage spaces 3. This allows the single plate portion 20 to regulate the amount of insertion of the insertion surfaces 41, which are the end faces of the plurality of battery modules 2.

[0057] 7, 17, etc., the edge of the plate portion 20 can be provided with a locking piece 26 that partially locks with the edge of the case body 11. This makes it easier to align the bottom surface 3B of the storage space 3 and the top surface 120A of the plate portion 20 on the same plane. It is also preferable to form the locking piece 26 thin and adjust the position of the locking piece 26 so that it does not interfere with the insertion of the battery module 2.

[0058] (Stopper Portion 21) The plate portion 20, 20' is provided with a plurality of stopper portions 21, 21'. As shown in Figures 10 and 11, when the battery module 2, 2' is inserted from the insertion opening 14 of the case body 11 toward the second surface 13, each stopper portion 21, 21' interferes with the insertion surface 41 of the battery module 2, 2', thereby restricting the amount of insertion. For this reason, the stopper portions 21, 21' are provided at positions corresponding to each storage space 3. In the example of Figure 10, etc., one stopper portion 21 is provided for each storage space 3, but the present invention is not limited to this configuration, and for example, a plurality of stopper portions may be provided for each storage space.

[0059] The stopper portion 21 only needs to interfere with the insertion surface 41 of the battery module 2 and prevent the battery module 2 from being pushed further back than the position of the stopper portion 21, so the stopper portion 21 can have any shape that facilitates interference. In the example shown in the perspective view of Figure 17, the stopper portion 21 is formed in an arch shape. Here, the art-shaped stopper portion 21 is formed in a semicircular shape in cross section. Such a stopper portion 21 has the advantage that it can be easily formed by punching when forming the plate portion 20 from a metal plate.

[0060] [Embodiment 2] In a power supply device according to embodiment 2 shown in Figure 18, a stopper portion 21B provided on a plate portion 20B is formed in a hood shape with an opening on one side. The hood-shaped opening of this stopper portion 21B interferes with, or abuts against, the insertion surface 41, which is the end surface of the battery module 2. This type of stopper portion 21B can also be easily formed by stamping a metal plate. Note that the stopper portion 21B in Figure 18 needs to be formed so that the hood-shaped opening faces the insertion surface 41 of the battery module 2. This is because if the stopper portion 21B were facing the wrong way, it may not be possible to prevent the battery module 2 from being pushed in along the inclined surface of the hood.

[0061] [Embodiment 3] In a power supply device according to embodiment 3 shown in FIG. 19 , stopper portions 21C on a plate portion 20C are formed by making U-shaped cuts in the metal plate portion 20 and raising them up. This configuration of stopper portions 21 also offers the advantage of being easily formed. The stopper portions 21C in FIG. 19 are preferably formed with the cuts facing the battery module 2. This is because, if they are positioned in the opposite direction, there is a concern that the raised stopper portions 21 may be toppled by the battery module 2 being pushed in. Alternatively, each stopper portion 21C may be rotated 90° in either direction from the state shown in FIG. 19 . This avoids the risk of the edge of the stopper portion 21C interfering with the insertion surface 41 of the battery module 2 and bending the stopper portion 21C in a direction that would cause it to topple over when pushed in.

[0062] In the above example, the plate portion 20 is formed from a metal plate. Metal plates are preferable because they are strong and easy to process. However, as shown in Figure 7 and other figures, it is necessary to consider insulation from the circuit board 30 fixed to the upper surface 120A of the plate portion 20, and care must be taken, such as adding an insulating sheet 34.

[0063] [Method of Manufacturing Power Supply Device] A method of manufacturing such a power supply device will be described below. Here, the power supply device 100 includes a plurality of battery modules 2 and a power supply case 10. Each of the plurality of battery modules 2 has a plurality of secondary battery cells connected thereto. The power supply case 10 includes a case body 11 and a plate portion 20. The case body 11 has a first surface 12 with a plurality of insertion / removal openings 14 for accommodating the plurality of battery modules 2 in an insertable / removable state, and a second surface 13 opposite the first surface 12. The plate portion 20 is fixed to a portion of the case body 11 and is formed as a separate member from the case body 11.

[0064] First, a plate member 20 is prepared that has stopper portions 21 that interfere with the insertion surfaces 41 of the battery modules 2 to restrict the amount of insertion when the battery modules 2 are inserted from the insertion openings 14 of the case body 11 toward the second surface 13 from each of the insertion surfaces 41, which are the end surfaces. Next, the plate member 20 is fixed to a part of the case body 11. By configuring the plate member 20 with the stopper portions 21 as a separate member from the case body 11, even if the length of the battery modules 2 to be inserted is changed, it can be accommodated by simply replacing the plate member 20 with the stopper portions 21 positioned accordingly, thereby avoiding the need to redesign the case body 11.

[0065] The step of preparing the plate portion 20 may include a step of determining a plate length D1 in the depth direction of the plate portion 20 so that D1 > Lmax - Lmin, where Lmax is the maximum value of the expected module length of the battery module 2 and Lmin is the minimum value of the expected module length of the battery module 2. This allows the position at which the stopper portion 21 is provided to be changed within the range of the plate length of the plate portion 20, making it possible to accommodate the entire range of expected module lengths of the battery module 2.

[0066] The power supply device, power supply case for the power supply device, and method for manufacturing the power supply device according to the present disclosure can be suitably used as a stationary power storage device, for example, a power supply device for home, business, or factory use, or as a backup power source for a data center.

[0067] 100, 100' Power supply device 1 Secondary battery cell 2 Battery module 3 Storage space 10 Power supply case 11 Case body 12 First surface 13 Second surface 14 Insertion / removal opening 15 First main body case 16 Second main body case 17 Third main body case 18 Fourth main body case 19 Partition plate 20, 20' 20B, 20C Plate portion 21, 21', 21B, 21C Stopper portion 22, 22' Plate side board fixing portion 24 Bottom opening 24' Recess 26 Locking piece 30, 30' Circuit board 32 Case side connector 34 Insulating sheet 36 Case side board fixing portion 41 Insertion surface 42 Exposed surface 43 Module housing; 43A First module case 43B Second module case; 44 Battery side connector 45 Internal assembly 46 Lead plate 600 Power supply device 602 Battery module 610 Power supply case 630 Electrical component 721 Stopper portion 800 Power supply device 802 Battery module 810 Power supply case 821 Stopper portion 832 Case side connector 844 Battery side connector 900 Power supply device 902 Battery module 910 Power supply case 921 Stopper portion 930 Circuit board L1, L2 Module length B1, B2 Board length D1 Plate length

Claims

1. A power supply device comprising: a plurality of battery modules, each having a plurality of secondary battery cells; and a power supply case housing the plurality of battery modules, wherein the power supply case comprises: a case body having a first surface with a plurality of insertion / removal openings through which the plurality of battery modules are respectively inserted and removed, and a second surface opposite the first surface; and a plate portion fixed to a part of the case body and constructed as a separate member from the case body, wherein the plate portion has stopper portions that interfere with each end face of the plurality of battery modules when the plurality of battery modules are inserted from each of the insertion / removal openings of the case body toward the second surface side.

2. A power supply device as claimed in claim 1, wherein the case body defines a plurality of storage spaces therein, each of which communicates with the plurality of insertion / removal openings and which respectively houses the plurality of battery modules, and wherein the end face of the plate portion is not exposed above the bottom surface of each of the plurality of storage spaces.

3. A power supply device as claimed in claim 1, wherein the inner surface of the case body, a mounting surface for mounting the plurality of battery modules and an upper surface of the plate portion are formed in the same plane.

4. A power supply device as claimed in claim 1, wherein the case body has a bottom opening formed by opening a portion of the bottom surface thereof, and the plate portion is arranged so as to close the bottom opening.

5. A power supply device as claimed in claim 1, further comprising a circuit board disposed inside said case body between the end faces of said plurality of battery modules and said second surface, said plate portion being provided with a plate-side board fixing portion for fixing a portion of said circuit board.

6. A power supply device according to claim 5, wherein said case body is provided with a case-side board fixing portion for fixing another part of said circuit board.

7. A power supply device according to claim 5, wherein the circuit board is placed in the case body in a position aligned with the insertion direction of the battery module.

8. A power supply device according to any one of claims 1 to 7, wherein the case body has the plurality of insertion / removal openings arranged side-by-side on the first surface.

9. A power supply device according to any one of claims 1 to 7, wherein the stopper portion is formed in a semicircular shape in a cross-sectional view.

10. A power supply device according to any one of claims 1 to 7, wherein the power supply device is a backup power supply for a data center.

11. A power supply case for a power supply device for storing a plurality of battery modules, each having a plurality of secondary battery cells, comprising: a case body having a first surface with a plurality of insertion / removal openings for storing the plurality of battery modules in an insertable / removable state, and a second surface opposite the first surface; and a plate portion fixed to a part of the case body and composed of a separate member from the case body, wherein the plate portion is provided with stopper portions that interfere with each end face of the plurality of battery modules to regulate the amount of insertion when the plurality of battery modules are inserted from each end face side of the plurality of battery modules through each insertion / removal opening of the case body toward the second surface side.

12. A method for manufacturing a power supply device comprising: a plurality of battery modules, each having a plurality of secondary battery cells; and a power supply case that houses the plurality of battery modules, wherein the power supply case comprises: a case body having a first surface with a plurality of insertion / removal openings that respectively store the plurality of battery modules in an insertable / removable state, and a second surface opposite the first surface; and a plate portion fixed to a part of the case body and made of a separate member from the case body, the method comprising: preparing the plate portion having stopper portions that interfere with each end face of the plurality of battery modules to regulate the amount of insertion when the plurality of battery modules are inserted from each of the insertion / removal openings of the case body toward the second surface side, and fixing the plate portion to a part of the case body.

13. A method for manufacturing a power supply device as described in claim 12, wherein the step of preparing the plate portion includes a step of determining a plate length D1 in the depth direction of the plate portion such that D1 > Lmax - Lmin, where Lmax is the expected maximum value of the module length of the plurality of battery modules and Lmin is the expected minimum value of the module length of the plurality of battery modules.

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