Power supply device

Abstract

The present invention achieves an effective waterproof structure with a simple structure while electrically connecting the inside and outside of a case. This power supply device comprises: a battery block formed from battery cells; and a case 10 accommodating the battery block. The battery block has an external terminal 20 of a metal rod 21 having a leading end that projects out of the case 10, and a cap 30 mounted on the external terminal 20. The external terminal 20 has a projecting part 22 projecting from an insertion hole 12 made in the case 10. The cap 30 has a cylindrical part 31 through which the projecting part 22 is inserted and a joining surface 32 joined to the outer surface of the case 10. An O-ring 40 disposed in a groove 23 made in a lateral surface 22a of the projecting part 22 or / and an inner surface 31a of the cylindrical part 31 is interposed between the lateral surface 22a of the projecting part 22 and the inner surface 31a of the cylindrical part 31. A waterproof adhesive member 50 is interposed between the joining surface 32 and the case 10. The O-ring 40 and the waterproof adhesive member 50 close respective gaps to form a waterproof structure.

Description

power supply

[0001] The present disclosure relates to a power supply device that has a waterproof function and allows electrical connection between the inside and outside of a case using external terminals that protrude from the case that houses a battery block.

[0002] Power supply devices used in vehicles such as electric motorcycles, construction machinery, and the like are used outdoors, so they can improve reliability by providing a waterproof structure while enabling electrical connection between waterproof and non-waterproof areas inside and outside the case. Power supply devices have been developed that are sealed with a waterproof structure while electrically connecting the inside and outside of the case (for example, Patent Document 1, etc.).

[0003] The power supply device 800 of Patent Document 1 in Figure 7 has a certain degree of waterproofing effect because a waterproof elastic ring (O-ring 840) arranged inside the case 810 is sandwiched between the case 810 and the bus bar 830 on the upper and lower planes to form a seal, but there is no waterproof structure at the crimped portion where the external terminal 820 is crimped to the bus bar 830, and water cannot be prevented from entering the crimped portion and further into the interior through the gaps between the external terminal 820 and the first nut 851 or ring member 852, resulting in the problem that it is not completely waterproof and also has a problem that the structure is complicated.

[0004] Also, for example, in the power supply device 900 shown in the schematic diagram of Figure 8, a fixing plate 911 is crimped to the external terminals 920, and the fixing plate 911 is screw-fixed to the case 910 with set screws 950. This configuration has the problem that the fixing plate 911 crimped to the external terminals 920 is larger in area than the external terminals 920, requiring installation space, and because the fixing plate 911 is screw-fixed to the case 910, it cannot be used when the case 910 has thin walls. In addition, the waterproof structure is achieved by an O-ring 940 interposed between the external terminals 920 and the waterproof wall of the case 910, which also has the problem of not being usable when the case has thin walls. Furthermore, the crimping of the fixing plate 911 and the screw-fixing to the case 910 cause problems with the connection and fixation strength of the external terminals 920, resulting in a decrease in waterproofing effectiveness.

[0005] JP 2018-10798 A

[0006] One object of the present disclosure is to provide a power supply device that can achieve an effective waterproof structure with a simple structure while enabling electrical connection between a waterproof area and a non-waterproof area. Another object of the present disclosure is to provide a power supply device with a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. 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.

[0007] A power supply device according to one embodiment of the present disclosure is a power supply device comprising a battery block composed of battery cells and a case that houses the battery block, wherein the battery block has an external terminal that is a metal rod whose tip protrudes outside the case and a cap that is attached to the external terminal, wherein the external terminal is inserted into an insertion hole provided in the case and has a protrusion that protrudes from the insertion hole, wherein the cap has a tubular portion with a hollow portion through which the protrusion is inserted and a joint surface that is joined to the outer surface of the case, wherein an O-ring that is placed in a groove provided on the side surface of the protrusion and / or the inner surface of the tubular portion is interposed between the side surface of the protrusion and the inner surface of the tubular portion, and a waterproof adhesive member is interposed between the joint surface and the case, and the O-ring and the waterproof adhesive member seal each gap to provide a waterproof structure.

[0008] The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area.The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin.

[0009] FIG. 1 is a schematic perspective view showing the waterproof structure of an external terminal of a power supply device according to embodiment 1. FIG. 2 is an exploded perspective view of the power supply device of FIG. 1. FIG. 3 is a schematic cross-sectional view taken along line III-III of FIG. 1. FIG. 4 is a schematic cross-sectional view of a cap according to another example. FIG. 5 is a schematic cross-sectional view of a cap according to another example. FIG. 6 is a schematic cross-sectional view of a cap according to another example. FIG. 7 is a schematic cross-sectional view of a waterproof structure of an external terminal of a power supply device according to a conventional example. FIG. 8 is a schematic cross-sectional view of a waterproof structure of an external terminal of a power supply device according to another conventional example.

[0010] The embodiments of the present disclosure may be specified by the following configurations and features: A power supply device according to one embodiment of the present disclosure is a power supply device including a battery block composed of battery cells and a case that houses the battery block, wherein the battery block has external terminals that are metal rods with their tips protruding outside the case and a cap attached to the external terminals, the external terminals are inserted into insertion holes provided in the case and have protrusions that protrude from the insertion holes, the cap has a tubular portion with a hollow portion through which the protrusions are inserted and a joint surface that is joined to the outer surface of the case, an O-ring disposed in a groove provided on a side surface of the protrusion and / or on the inner surface of the tubular portion is interposed between the side surface of the protrusion and the inner surface of the tubular portion, a waterproof adhesive member is interposed between the joint surface and the case, and the O-ring and the waterproof adhesive member seal each gap to provide a waterproof structure.

[0011] The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed in a small space or even when the waterproof case has thin walls. This is because the above power supply device includes a battery block with an external terminal of a metal rod whose tip protrudes outside the case, a cap attached to the external terminal, a tubular portion with a hollow portion through which the protrusion passes and a mating surface bonded to the outer surface of the case, an O-ring placed in the groove interposed between the side of the protrusion and the inner surface of the tubular portion, and a waterproof adhesive interposed between the mating surface and the case to seal the waterproof structure.

[0012] For example, in the structure shown in FIG. 8 , a fixing plate 911 is connected to an external terminal 920 by crimping, for example, with a clinching spacer, and the fixing plate 911 is connected and fixed to the wall of the case 910 by screwing with a set screw 950. This structure requires a large installation space including the fixing plate 911, and is therefore not usable when the wall of the case 910 is thin. That is, the fixing plate 911 in FIG. 9 has terminal insertion holes for inserting the external terminals 920 and screw insertion holes around the outer periphery of the terminal insertion holes, spaced apart from the terminal insertion holes, for screwing in a plurality of fixing set screws 950, preferably four or more. The fixing plate 911 is larger than the area of ​​the external terminals 920 and requires a large installation space. Furthermore, because the fixing plate 911 is fixed to the case 910 with the set screw 950, the wall of the case 910 must be thick, which creates a problem of insufficient strength when the wall is thin. Although the connection and fastening strength can be improved by threading the set screw 950 through the case 910 and into a nut, if the set screw 950 penetrates the case 910, a new waterproof structure for the set screw 950 is required. Furthermore, if the set screw 950 does not penetrate the case 910, the case 910 must be thicker and have a more complex structure to ensure the connection and fastening strength, which increases material and manufacturing costs. Furthermore, it is difficult to ensure sufficient connection and fastening strength using a self-tapping screw threaded into the wall of a resin case 910. While a thick metal case 910 can ensure connection and fastening strength, it has the problem of significantly increasing material costs and mass. Furthermore, the power supply unit 900 of FIG. 8 interposes an O-ring 940 between the wall of the case 910 and the external terminal 920. However, if the wall of the case 910 is thin, it is difficult to achieve a stable and reliable seal. Furthermore, insufficient connection and fastening strength between the external terminal 920 and the case 910 reduces the waterproof effect. If the external terminal 920 is tilted and a relative positional misalignment occurs between the external terminal 920 and the case 910 that clamp the O-ring 940, the O-ring 940 cannot be clamped properly, and gaps will form between the O-ring 940 and the external terminal 920 or the case 910, reducing the waterproof effect and possibly reducing the durability of the O-ring 940. Maintaining a predetermined posture of the external terminal and the strength of the connection and fixation between the external terminal and the case are important factors in ensuring the waterproof structure and effect.Furthermore, when using the set screw 950, the power supply unit 900 mounted on an electric vehicle, a construction vehicle, equipment, etc. is susceptible to the set screw 950 loosening due to vibrations and shocks during driving and use, and if the set screw 950 loosens, the O-ring 940 cannot be securely clamped, which presents a problem of reduced waterproofing.

[0013] In contrast, the power supply device disclosed herein does not require a fixing plate to be crimped to the external terminal or a space for its placement. Furthermore, the power supply device disclosed herein achieves a waterproof structure by bonding and joining the cap and case wall with waterproof adhesive materials such as waterproof double-sided tape or waterproof glue, without fastening with set screws, eliminating the need for thick case walls for screw fastening. Furthermore, the waterproof structure can be achieved by interposing an O-ring between the external terminal and the cap, rather than between the external terminal and the case wall as shown in the conventional example of FIG. 8 , and the placement of the O-ring does not restrict the thickness of the case wall. The O-ring can be placed in a small space in the groove to achieve the waterproof structure. The waterproof adhesive material firmly bonds and joins the cap and case wall, providing a connection and fixing strength greater than that achieved by a combination of crimping and screw fastening, as shown in the conventional power supply device 900 illustrated in FIG. 8 , and also improving durability. The above configuration does not require a fixing plate, and has a simple structure in which the cap is placed on the external terminal, reducing the number of parts, facilitating manufacturing and reducing costs, and allowing the waterproof structure to be completed outside the case. The above configuration has the advantage that an O-ring is interposed between the external terminal and the inner surface of the cap, and the joining surface of the cap and the outer surface of the case are bonded and joined with a waterproof adhesive such as waterproof double-sided tape, thereby achieving a waterproof structure from two directions, while also being able to clamp and support the external terminal with the tubular part of the cap, and to achieve strong adhesion and joining with the waterproof adhesive on the joining surface.

[0014] Furthermore, the tubular portion of the cap not only covers the external terminal (metal rod) in all directions and is suitable for clamping an endless O-ring, but also has the advantage that the tubular portion, which is tall in the Z-axis direction, clamps the inserted external terminal (metal rod) from both sides with a pair of opposing inner surfaces in all directions, effectively preventing and reducing tilt of the external terminal (metal rod) and relative movement and misalignment between the outer surface of the external terminal that clamps the O-ring and the inner surface of the tubular portion. Furthermore, by extending the height of the tubular portion, the cap can efficiently improve these effects at low cost without substantially increasing costs or substantially changing the configuration or shape of other components such as the case or external terminal. The cap saves space by expanding the joining surface, easily improving waterproof performance, connection, and fixing strength. The cap can be made into a separate component from the case or external terminal, eliminating restrictions on the materials of other components and allowing for selection of materials, shapes, hardness, etc. suitable for waterproofing and joining.

[0015] Power supplies can be made waterproof by encasing battery blocks in waterproof bags, pouches, shrink tubing, or other materials and then storing them in a case. However, waterproof bags containing a large number of battery cells are heavy, making them difficult to move and store, resulting in laborious manufacturing and increased manufacturing costs. Furthermore, the waterproof bags can be damaged or torn by vibration, impact, or dropping of the power supply or the product containing it. In contrast, the power supply described above does not require waterproof bags, and even when it contains a large number of battery cells, there is no need to move a large number of battery cells at once; instead, any number of battery cells can be moved at the time of manufacturing. The simple structure of attaching a cap to the protrusion and using an O-ring and waterproof adhesive eliminates the difficulties of moving the battery cells, storing them in the case, and manufacturing processes, without significant increase in costs, and without the risk of damage from vibration or impact, thereby solving these problems.

[0016] In addition, in the power supply device according to another embodiment of the present disclosure, in the above configuration, the cap can have a tubular portion that is open at both ends. The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the waterproof case has thin walls. Furthermore, a cap having a tubular portion that is open at both ends can be attached to the protruding portion of the external terminal, and an external connection portion that connects to an external wiring component outside the case can be provided at the tip of the protruding portion exposed from the tubular portion.

[0017] Furthermore, in a power supply device according to another embodiment of the present disclosure, in any of the above configurations, the mating surface can be located on the bottom surface of the cap. This configuration has the advantage of being able to achieve an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. This configuration also has the advantage of being able to achieve a waterproof structure that can be installed in small spaces or when the walls of the waterproof case are thin. The O-ring interposed between the side of the protrusion and the inner surface of the tubular portion and the waterproof adhesive bonded to the mating surface on the bottom surface of the cap can be positioned non-coplanar, and the O-ring and waterproof adhesive can be positioned in a twisted position. This allows for a two-way waterproof structure using the O-ring and waterproof adhesive, while efficiently achieving both clamping and support of the external terminals by the tubular portion of the cap and strong adhesion and bonding by the waterproof adhesive on the mating surface.

[0018] Furthermore, in any of the above-described power supply devices according to other embodiments of the present disclosure, the O-ring may be positioned away from the mating surface and staggered relative to the mating surface. The above configuration has the advantage of realizing an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of realizing a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. The above configuration has the advantage of efficiently achieving both clamping and support of the external terminals by the tubular portion of the cap and strong adhesion and bonding by the waterproof adhesive on the mating surface while realizing a waterproof structure from two directions using the O-ring and waterproof adhesive via the cap.

[0019] Furthermore, in a power supply device according to another embodiment of the present disclosure, in any of the above configurations, a groove can be provided on the side of the protrusion. The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. The above configuration has the advantage of being easy to attach and install O-rings and caps, and easy to position the groove in the appropriate position, allowing the groove to maintain the position and orientation of the O-ring, thereby realizing a stable waterproof structure.

[0020] Furthermore, in a power supply device according to another embodiment of the present disclosure, in any of the above configurations, the outer shape of the protrusion can be circular, and the tubular portion of the cap can be cylindrical. The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. The above configuration has the advantages of reducing component costs, reliably and efficiently clamping an annular O-ring on the inner surface of the cylindrical portion, uniformly clamping the O-ring, and effectively achieving waterproofing and preventing relative misalignment.

[0021] Furthermore, in a power supply device according to another embodiment of the present disclosure, in any of the above configurations, the cap may be connected to the cylindrical portion, have a flange portion protruding outward from the cylindrical portion, and have a joint surface on the bottom surface of the flange portion. The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. The ring-shaped flange portion extending outward from the periphery of the cylindrical portion has a joint surface on the bottom surface that is bonded and joined with a waterproof adhesive, thereby achieving both a waterproof structure and a strong connection and fixation. Furthermore, the area of ​​the ring-shaped flange portion extending outward can be increased to easily and efficiently improve these effects.

[0022] Furthermore, in a power supply device according to another embodiment of the present disclosure, in any of the above configurations, the waterproof adhesive member can be double-sided tape. The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. Waterproof double-sided tape is easy to obtain at low cost, is not limited by wall thickness, can simultaneously achieve reliable waterproofing and strong bonding, and is easily visible during the manufacturing process.

[0023] Furthermore, in a power supply device according to another embodiment of the present disclosure, in any of the above configurations, the cap can be made of resin or metal. The above configuration has the advantage of being able to realize an effective waterproof structure with a simple structure while enabling electrical connection between the waterproof area and the non-waterproof area. The above configuration also has the advantage of being able to realize a waterproof structure that can be installed even in small spaces or when the walls of the waterproof case are thin. Resin has the advantage of being easy to mold at low cost.

[0024] 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 specified or limited thereto. Furthermore, this specification does not in any way specify the components set forth in the claims as components 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 served by one component, or conversely, the functions of one component may be shared by multiple components.

[0025] The battery device 100 of the present disclosure is not limited to a specific external device or application, but can be used primarily as a power source for electric devices used outdoors, such as a driving power source for mobile devices such as electric carts, electric scooters, assisted bicycles, hybrid vehicles, and electric automobiles; a power source for construction machinery used on civil engineering and building sites; a power source for portable electrical devices such as radios, power tools, and electric cleaners; or a stationary power storage device such as a backup power source for servers, or a power supply for home, office, or factory use. The battery device of the present disclosure is not limited to a specific application for the built-in or connected device, and can be used for all power supplies that require electrical connections inside and outside the case and a waterproof structure. Below, as one embodiment of the present disclosure, a power supply device used as a driving power source for a tamping rammer that solidifies the ground using its own weight and impact is described. [Embodiment 1]

[0026] The power supply device 100 according to the first embodiment shown in Figures 1 to 3 includes a battery block and a waterproof case 10 that houses the battery block. Figure 1 is a schematic perspective view showing the waterproof structure and connection state of the external terminals 20 of the power supply device 100 according to the first embodiment, Figure 2 is an exploded perspective view of Figure 1, and Figure 3 is a schematic cross-sectional view of Figure 1. Figures 4 to 6 show schematic cross-sectional views of a cap 30 according to another embodiment. (Case 10)

[0027] Case 10 is a case that houses the battery block and is an exterior case that forms the outer shape of power supply unit 100. Case 10 is covered with waterproof walls 11, houses the battery block inside, and is a waterproof case that is sealed with a waterproof structure made of a molded insulating material to prevent water from entering the case, but case 10 does not necessarily have to have a completely waterproof structure. Case 10 can also be structured, for example, by providing a drain hole or the like at the bottom so that water that enters the inside can be drained from below.

[0028] The case 10 can be molded from an insulating plastic such as ABS resin. The case 10 can be configured to be separable into multiple sections, and can be composed of a main body with insertion holes 12 and a lid, which is sealed with packing, a gasket, or an O-ring 40 sandwiched between them after the battery block is housed inside. The case 10 can be divided into two sections, for example, along the middle of the peripheral wall, and connected and secured together in a waterproof structure using screws. However, the two cases 10 can also be secured together using methods such as a fitting method, or by heat welding or adhesive bonding. The case 10 can be designed in a variety of shapes depending on the application, purpose, and usage of the power supply device, as well as the outer shape and number of battery cells and battery blocks to be housed.

[0029] The case 10 has insertion holes 12 that penetrate the wall surface 11 for inserting the external terminals 20. The external terminals 20 have protrusions 22 at their tip ends that protrude from the insertion holes 12 to the outside of the case 10. The insertion holes 12 are slightly larger in shape than the outer shape of the protrusions 22 of the external terminals 20 to be inserted, allowing the protrusions 22 to be inserted smoothly. The case 10 has insertion holes 12 at predetermined positions corresponding to the number of external terminals 20. The case 10 in FIG. 2 has circular insertion holes 12 that correspond to the shape of the circular rods 21A of the protrusions 22. The external terminals 20 in FIG. 3 have protrusions 22 that protrude perpendicularly to the insertion holes 12 to the outside of the case 10. In the power supply unit 100, by attaching the cap 30 to the protruding portion 22 with the external terminals 20 inserted into the insertion holes 12, an O-ring 40 is sandwiched between the side surface 22a of the protruding portion 22 and the inner surface 31a of the tubular portion 31 of the cap 30, thereby providing a waterproof seal. As illustrated in FIG. 2 , the case 10 can simplify its shape and structure by making the periphery of the insertion holes 12, including the case joint 13, flat. However, the case 10 may have shapes and structures on the inside and outside of the wall surface 11 necessary for functionality such as improving the strength of the case 10, or for aesthetic reasons. The insertion holes 12 may have a thickness, shape, and structure that can position, support, and hold the inserted external terminals 20. For example, steps or irregularities can be provided at the base of the external terminals 20, which can abut against the periphery of the insertion holes 12 to position the external terminals 20. Furthermore, the case 10 has a cylindrical portion 31 extending from the insertion hole 12 into the case 10, and the cylindrical portion 31 or the projections and recesses provided on the cylindrical portion 31 can position, support, and hold the non-protruding portion 25 of the external terminal 20.

[0030] The case 10 has a case joint 13 to which the joint surface 32 of the cap 30 is joined and bonded. The case joint 13 is arranged along the periphery of the insertion hole 12. The case joint 13 is shaped to match the shape of the cap 30 (flange portion 33) to be joined and the interposed waterproof adhesive member 50. The case joint 13 in FIGS. 2 and 3 is ring-shaped to match the shape of the ring-shaped flange portion 33 and is provided along the periphery of the insertion hole 12. The planar case joint 13 can be firmly and tightly bonded to the joint surface 32 of the flange portion 33 of the planar cap 30 via the waterproof adhesive member 50. The case joint 13 tightly joins and firmly connects the bottom surface of the cap 30, thereby improving the strength with which the tubular portion 31 surrounding the external terminal 20 supports and clamps the external terminal 20. The case joint 13 can be integral with the case 10 or can be a separate member. When the case 10 is made of metal, the external terminals 20 can be insulated from the metal case 10 by interposing an insulating case joint 13. The case joint 13 and its outer periphery can have a flat surface, a curved surface, an inclined surface, or the like, and can also have steps, irregularities, or grooves.

[0031] The battery block has one or more battery cells. The battery block has a holder that positions the battery cells in a predetermined position and orientation, and internal connectors such as lead plates and bus bars that connect the multiple battery cells in series or parallel. The multiple battery cells are positioned in a predetermined position and orientation in the holder and connected in series or parallel via the internal connectors. Any rechargeable secondary battery can be used as the battery cells. The battery cells are rechargeable, and non-aqueous secondary batteries such as lithium-ion batteries can be used to increase the charge / discharge capacity relative to their volume and weight. However, this disclosure does not limit the battery cells to lithium-ion batteries. All secondary batteries can be used, including known and currently used secondary batteries such as lithium polymer batteries, nickel-metal hydride batteries, and nickel-cadmium batteries, as well as all-solid-state batteries to be developed in the future. The battery cells can be of any shape, such as cylindrical, prismatic, or thin. The number and arrangement of the battery cells are not specified, and any number and arrangement can be adopted as appropriate. Each secondary battery cell has a positive and negative electrode.

[0032] The holder is a member for holding multiple battery cells. The holder is divided into multiple sub-holders that clamp and hold the secondary battery cells. The multiple secondary battery cells are connected in series or parallel via lead plates or the like. The number of series connections or parallel connections can be set as desired according to the required specifications. The battery block may also be composed of multiple sub-blocks, with multiple battery cells housed in each sub-block. The holder may also have a mechanism or structure for holding or positioning the lead plates. The holder is made of a material with excellent insulating and heat-resistant properties, such as a resin such as polycarbonate or ABS. (External terminal 20)

[0033] The battery block has external terminals 20 that are metal rods 21 whose tips protrude outside the case 10, and caps 30 that are attached to the external terminals 20. The external terminals 20 are directly or indirectly connected to the electrodes of the battery cells to output or input power to the battery block. The external terminals 20 have protruding portions 22 that protrude outside the case 10 through the insertion holes 12, and a non-protruding portion 25 other than the protruding portions 22. The metal rods 21 may be rod-shaped, shaft-shaped, columnar, cylindrical, or plate-shaped. The external terminals 20 have protruding portions 22 that partially protrude outside the case 10. The external terminals 20 illustrated in FIGS. 1 and 3 have protruding portions 22 that protrude outward from the insertion holes 12 provided in the wall surface 11 of the case 10.

[0034] The external terminal 20 in Figures 2 and 3 is a metal rod 21 having a circular rod 21A with a circular (including substantially circular and elliptical) outer shape in a horizontal cross section and a non-circular rod 21B with a non-circular outer shape. The external terminal 20 of the metal rod 21 has a protruding portion 22 at its tip end exposed on the surface of the case 10 as the circular rod 21A, and a non-protruding portion 25 at its rear end disposed inside the case 10 as the non-circular rod 21B. The external terminal 20 in Figures 2 and 3 has a cylindrical protruding portion 22 at its tip end and a non-protruding portion 25 with a pair of flat portions at its rear end. The protruding portion 22 in Figure 2 has a curved outer shape and is a circular rod 21A with a circular cross-sectional outer shape. Part or all of the circular rod 21A can be the protruding portion 22. The external terminal 20 is clamped by the inner surface 31a of the tubular portion 31 of the cap 30, which is attached to the protruding portion 22, and the joint surface 32 on the bottom of the cap 30 is joined to the outer surface of the case 10 via a waterproof adhesive member 50, thereby connecting the external terminal 20. The circular rod 21A does not necessarily have a circular cross-sectional shape and can be elliptical. The non-circular rod 21B also does not necessarily have the shape shown in the figure and can be polygonal, for example. The maximum outer diameter of the non-circular rod 21B of the external terminal 20 can be equal to or larger than the maximum outer diameter of the circular rod 21A. The diameter of the circular rod 21A can be smaller than the diameter of the circumscribing circle or inscribing circle of the non-circular rod 21B. The external terminal 20 has a step corresponding to the difference in diameter between the circular rod 21A and the non-circular rod 21B. This determines the protruding length of the external terminal 20 (the height of the protruding portion 22), allowing the external terminal 20 inserted into the insertion hole 12 to be positioned in a predetermined posture. The external terminal 20 can be provided with a step to determine the length by which the external terminal 20 protrudes (the height of the protrusion 22), and the maximum outer diameter of the non-circular rod 21B can also be made smaller than the maximum outer diameter of the circular rod 21A. Note that the entire external terminal 20 can also be made into a circular rod 21A or a non-circular rod 21B.

[0035] The external terminal 20 shown in FIG. 2 has a groove 23 for accommodating an O-ring 40 on the side surface 22a of the protruding portion 22 of the circular rod 21A. The groove 23 is annular and opens toward the direction in which the O-ring 40 is exposed from the circular rod 21A. The groove 23 is a cylindrical groove that seals the inner and outer diameter surfaces of the O-ring 40. The groove 23 is preferably a square groove as shown in FIG. 3, but can have other shapes, such as a dovetail groove or an L-shaped groove. The groove 23 can hold the O-ring 40 therein and press down on one side (the external terminal 20 side). As shown in FIG. 3, when the circular rod 21A of the protruding portion 22 is inserted into the insertion hole 12, the O-ring 40 is disposed in the groove 23 in a state where it is crushed between the groove 23 of the circular rod 21A and the inner surface 31a of the tubular portion 31 of the cap 30, thereby sealing the gap between the circular rod 21A of the protruding portion 22 and the cap 30 in a waterproof structure. The outer diameter of the circular rod 21A is smaller than the inner diameter of the cylindrical portion 31 of the cap 30, leaving a small gap, for example 0.1 mm to 0.5 mm, between the circular rod 21A and the inner surface 31a of the cylindrical portion 31, which is sealed in a waterproof structure by a packing O-ring 40. The diameter of the ring portion of the O-ring 40 is greater than the depth of the groove 23, and it is compressed by the groove 23 of the protrusion 22 and the inner surface 31a of the cylindrical portion 31, causing elastic deformation and sealing the gap between the protrusion 22 and the cylindrical portion 31 in a waterproof structure. The configuration sealing with the groove 23 and the O-ring 40 provides waterproofing in a small space, is simple in structure, easy to install, and is cost-effective.

[0036] The groove 23 determines the position of the O-ring 40 and can be provided within the range of the side surface 22a of the protrusion 22, and is located at a height below the cylindrical portion 31 of the cap 30 in the attached position. The groove 23 in FIGS. 1 to 3 is located away from the case joint 13, and the groove 23 and the case joint 13 are located in a twisted position (intersecting position). The groove 23 is provided annularly along the circumference on the side surface 22a of the protrusion 22 of the circular rod 21A, and the case joint 13 is located in an X-axis and Y-axis plane that is at a different height from the groove 23. This arrangement configuration realizes a waterproof structure between the O-ring 40 and the waterproof adhesive member 50, while efficiently achieving both clamping and support of the external terminal 20 by the cylindrical portion 31 of the cap 30 and strong adhesion and bonding by the waterproof adhesive member 50 on the joint surface 32.

[0037] The external terminal 20 is a metal rod 21 made of a metal with low electrical resistance, such as nickel, iron or an iron alloy, or copper or a copper alloy, the surface of which is plated with nickel or the like, and processed into a long, thin rod shape.

[0038] 2 and 3 are provided on the side surface 22a of the protruding portion 22, but the groove 23 can also be provided on the inner surface 31a of the cylindrical portion 31 of the cap 30, or can be provided on both the side surface 22a of the protruding portion 22 and the inner surface 31a of the cylindrical portion 31. The groove 23 provided on the side surface 22a of the protruding portion 22 makes it easy to attach the O-ring 40 and the cap 30, and can achieve a stable waterproof structure.

[0039] The external terminal 20 has an external connection portion at its tip end protruding portion 22 that connects to external wiring components outside the case 10, and an internal connection portion at its rear end non-protruding portion 25 that connects to internal wiring components inside the case 10, electrically connecting the waterproof area inside the case 10 to the non-waterproof area outside the case 10. The external connection portion is connected to an external device via a crimp terminal or the like, and the internal connection portion is connected to the battery block and the electrodes of the multiple battery cells that make up the battery block via a lead plate or bus bar or the like. The external terminal 20 of the metal rod 21 in Figures 1 to 3 has a female threaded hole 26 opening at its tip. A set screw is threaded into the female threaded hole 26 to secure external wiring components, such as a washer portion of a contact terminal of an external connection lead, to the external terminal 20. The protruding portion 22 contacts the tip and tip surface of the metal rod 21 without the external wiring components coming into contact with the case 10, allowing them to be securely fixed by the set screw. 1 to 3, the external terminal 20 of the metal rod 21 has an insertion hole 27 at the rear end formed as a female screw hole 28, which can be threaded into to connect and fix an internal connection member. The shapes and structures of the external connection portion and the internal connection portion can be determined according to the members to be connected, and in addition to those shown, for example, the front end can be provided with an insertion hole 12 and a female screw hole similar to those at the rear end in Fig. 2, etc., or the rear end can be provided with a female screw hole similar to those at the front end in Fig. 2, etc. Furthermore, the external terminal 20 of the metal rod 21 can be provided with male screw portions at its front and rear ends, and external connection leads, contact terminals of internal connection leads, and washers can be fixed to the external terminal 20 with nuts.

[0040] The overall length of the metal rod 21, which is the external terminal 20, has an external connection portion and an internal connection portion, and is long enough to connect to external wiring components and internal wiring components. The outer shape of the circular rod 21A of the protrusion 22 is slightly smaller than the inner shape of the insertion hole 12, allowing the protrusion 22 to be smoothly inserted into the insertion hole 12. The external terminal 20 can be rod-shaped, shaft-shaped, column-shaped, cylindrical, or plate-shaped, either entirely or partially, and can have a curved surface, flat surface, tapered surface, step, unevenness, or groove on its outer surface. The metal rod 21 of the external terminal 20 can have the same or different cross-sectional shapes, and can be partially different shapes. (Cap 30)

[0041] The cap 30 has a tubular portion 31 having a hollow portion through which the protrusion 22 is inserted, and a joint surface 32 that is joined to the outer surface of the case 10. By providing the joint surface 32 that is joined to the outer surface of the case 10 on the bottom surface of the cap 30, the waterproof structure can be completed outside the case 10. The cap 30 in Fig. 2 has a cylindrical portion 31X having a hollow portion through which the protrusion 22 of the circular rod 21A is inserted, and a flange portion 33 that is connected to the cylindrical portion 31X, protrudes outward from the cylindrical portion 31X, and extends concentrically outward.

[0042] The cap 30 is attached to the protruding portion 22 when the external terminals 20 are inserted into the insertion holes 12 of the case 10, thereby achieving a waterproof structure for the external terminals 20. As illustrated in FIGS. 1 and 3 , the cap 30 is fitted to partially cover the side surface 22a of the protruding portion 22 of the circular rod 21A. In the cap 30 shown in FIGS. 2 and 3 , the cylindrical portion 31X is open at both the top and bottom, and the tip of the protruding portion 22 of the circular rod 21A passes through the cylindrical portion 31X and is exposed. The cap 30 is inserted until the joint surface 32 on the bottom surface abuts the upper surface of the wall surface 11 of the case 10, and is attached and fitted to the lower part of the protruding portion 22. The joint surface 32 faces the outer surface (the upper surface in FIG. 3 ) of the wall surface 11 of the case 10, and is adhered and bonded to the outer surface of the wall surface 11 of the case 10 via a waterproof adhesive member 50. The planar joint surface 32 is compatible with the planar case joint portion 13, realizing a strong joint, and also allowing the shape and structure of the case 10 to be simplified.

[0043] The cap 30 sandwiches an O-ring 40 between its inner surface 31a and the outer surface (side surface 22a) of the metal rod 21, providing a seal between the inner and outer diameter surfaces of the O-ring 40 in the horizontal direction of the X-axis and Y-axis plane. The cap 30 sandwiches the O-ring 40 between the inner surface 31a of the cylindrical portion 31 and the side surface 22a of the external terminal 20, providing a waterproof structure, and the joining surface 32 is joined to the outer surface of the case 10 via a waterproof adhesive member 50 such as double-sided tape 51, providing a waterproof structure. The cylindrical portion 31X covers the metal rod 21 of the external terminal 20 in all directions, allowing the endless O-ring 40 to be evenly sandwiched without or with little bias. The cylindrical portion 31X further has a height in the Z-axis direction, and thus the pair of opposing inner surfaces 31a clamp the inserted external terminal 20 (metal rod 21) from both outside in all directions, thereby effectively preventing and reducing tilting of the external terminal 20 (metal rod 21) and relative movement and misalignment between the outer surface of the external terminal 20 that clamps the O-ring 40 and the inner surface 31a of the cylindrical portion 31. The external terminal 20 is connected to external and internal wiring components via external connection portions and internal connection portions, and vibrations and shocks from the power supply unit 100 and the devices that house it are transmitted and tension is generated, causing tilting of the external terminal 20 and relative misalignment between the outer surface of the external terminal 20 and the inner surface 31a of the cylindrical portion 31, but the cap 30 can effectively prevent this. Furthermore, by extending the height of the cylindrical portion 31, the cap 30 has the advantage of efficiently further improving the above-mentioned effects at low cost without substantial cost increases or substantial changes to the configuration or shape of other components, such as the case 10 or the external terminal 20. The height of the cylindrical portion 31X is set to a height that allows surface contact with the protruding portion 22, including the O-ring 40 and its upper and lower ranges, thereby ensuring stable clamping of the O-ring 40. Furthermore, the height of the cylindrical portion 31X is set to a height that prevents tilting of the external terminal 20 of the metal rod 21, thereby preventing tilting of the clamped external terminal 20. Furthermore, the height of the cylindrical portion 31X is set to a height that is equal to or less than the height of the protruding portion 22, thereby exposing the end face and side surface 22a of the tip of the protruding portion 22 of the metal rod 21 for external wiring. The above-mentioned cap 30 has the advantage of requiring very little space for its installation, and can be positioned in a location that does not restrict or obstruct the placement of external wiring or peripheral components.

[0044] As shown in FIG. 3 , the vertical cross section of the cap 30 can be L-shaped. The tubular portion 31 (cylindrical portion 31X) extends in the Z-axis direction parallel to the outer surface of the external terminal 20, and the flange portion 33 is perpendicularly connected to the cylindrical portion 31X and extends outward from the lower end of the cylindrical portion 31X. The flange portion 33 is ring-shaped and extends annularly outward in all directions along the X- and Y-axis plane of the cylindrical portion 31X. The L-shaped cap 30 allows the thickness of the tubular portion 31 and flange portion 33, which sandwich the O-ring 40, to be determined and adjusted, and also reduces material costs. In addition to the L-shaped vertical cross section of the cap 30 shown in FIG. 3 , it can also be polygonal, such as a trapezoid (including a substantially trapezoid) as shown in FIG. 4 , a triangle (including a substantially triangular) as shown in FIG. 5 , or a rectangle (including a substantially rectangular) with a thickness toward the joining surface 32 as shown in FIG. 6 . It can also be irregular, conforming to the outer surfaces of the external terminal 20 and the case 10. The cap 30 of Figures 4 to 6 has improved strength of the connection between the cylindrical portion 31X and the mating surface 32 compared to Figure 3, which can be reflected in the support and connection of the external terminal 20. The cap 30 has an inner surface 31a of the cylindrical portion 31 and a mating surface 32 shaped to match the opposing external terminal 20 and case 10, respectively, and the rest of the cap can be flat, inclined, curved, or a combination of any of these. The cylindrical portion 31X and the flange portion 33 can have the same or different thicknesses. The cylindrical portion 31X has a thickness and material that allows it to be sealed by clamping an O-ring 40. Furthermore, in order to improve and strengthen the support, clamping, and tilt prevention of the external terminal 20 by the cylindrical portion 31X to the metal rod 21, the height and thickness of the cylindrical portion 31X can be increased and a material with high hardness can be used, and further, the thickness of the flange portion 33 and the connecting portion between the cylindrical portion 31X and the flange portion 33 can be increased, a material with high hardness can be used, and the area of ​​the flange portion 33 can be expanded, thereby improving the connection and fixing strength between the joining surface 32 and the case 10. Furthermore, the cylindrical portion 31 can extend below the top surface of the case 10 to cover the periphery of the external terminal 20 inside the case 10. The cap 30 is small and inexpensive, and it is possible to suppress cost increases associated with changes in shape, thickness, the height of the cylindrical portion 31, and the width of the flange portion 33.

[0045] The cap 30 can be molded entirely or partially from resin or metal. The cap 30 can be molded from insulating materials such as PC, POM, PA, PBT, PPE, PP, PE, PET, PBT, PS, PVC, ABS, PMMA, PEEK, PPS, PTFE, FEP, PFA, AF, LCP, PI, PES, PEI, fluororesin, MC nylon, rubber, silicone, elastomer, or resin. It can also be manufactured from metallic materials such as stainless steel, iron, aluminum, copper, or alloys containing any of these. The surface of a resin-made cap can be coated or plated with a metal material, or the surface of a metal-made cap can be coated with a resin material. Resin materials have the advantages of light weight, ease of molding, and low cost, while metal materials have the advantages of high strength and rigidity. The cap 30 is appropriately determined depending on the size and material of the O-ring 40. Furthermore, by making the hardness of the resin of the cap 30 higher than that of the resin of the case 10, the support and clamping effect of the external terminal 20 can be improved, and cost-effectiveness can be further improved. (O-ring 40)

[0046] The cap 30 has an O-ring 40 interposed between the inner surface 31a of the cylindrical portion 31 and the outer surface of the protruding portion 22. The O-ring 40 is sandwiched between the cylindrical portion 31X and the metal rod 21 and elastically deforms, generating a repulsive force to create a waterproof seal. The O-ring 40 is an endless annular body shaped to seal the side surface 22a of the protruding portion 22 and the inner surface 31a of the cylindrical portion 31X. For the protruding portion 22 of the circular rod 21A of the external terminal 20, which has a circular horizontal cross-sectional outer shape, a circular O-ring 40 is preferred. When the O-ring 40 is installed in the groove 23, the diameter of the O-ring 40 is greater than the depth of the groove 23. Therefore, when the O-ring 40 is sandwiched between the cap and compressed, a crushing margin is created, generating a repulsive force due to its elasticity, creating a tight seal and preventing the inflow of liquid (self-sealing effect). The O-ring 40 generates contact pressure (repulsion pressure) when pressure is applied, and seals (tightly seals) the objects sandwiched between them with the contact pressure. The O-ring 40's contact pressure increases in response to fluid pressure, and even if fluid pressure is added to the contact pressure, the maximum contact pressure is higher than the pressure of the fluid to be sealed, resulting in a seal (self-sealing). When the O-ring 40 is fitted into the groove 23 and pressed and clamped by the inner surface 31a of the cap 30 (cylindrical portion 31X), the compressed O-ring 40 generates a repulsion force that attempts to return to its pre-compression shape, blocking and sealing gaps through which water (fluid) can pass. Waterproof structures using O-rings 40 can seal without complex structures or shapes, are inexpensive, have standardized sizes, are available in a wide variety, and are easy to procure. Unlike injection molding, the presence or absence of the O-ring 40 can be visually confirmed, preventing it from being forgotten during manufacturing.

[0047] The O-ring 40 is a circular ring-shaped body in a top view, and its cross-sectional shape can be circular, elliptical, or rectangular (square ring). A square ring can increase the sealing surface area. The O-ring 40 can be made of rubber, resin, or foam, such as NBR (nitrile rubber), silicone, Viton, EPDM (ethylene propylene diene propylene), chloroprene, urethane, acrylic, hydrogenated nitrile, or fluorinated resin. (Waterproof adhesive member 50)

[0048] The waterproof adhesive member 50 is interposed between the joining surface 32 and the case 10, bonding and joining them together to form a waterproof structure. The waterproof adhesive member 50 can join the case 10 and the cap 30 without being restricted by the thickness of the case 10, thereby stably achieving a waterproof structure outside the case 10. It has the advantage of requiring fewer components than a set screw, resulting in a simpler configuration and lower cost. The waterproof adhesive member 50 can be any material that can bond and adhere the joining surface 32 and the case 10 to seal the gap and create a waterproof structure, such as waterproof double-sided tape 51 or adhesive, but double-sided tape 51 is preferred. Double-sided tape 51 allows visualization of the joining area and waterproof area through its placement, size, and shape, and allows adjustment of the bonding strength through the material, thickness, and area, thereby firmly bonding the joining surface 32 to the case 10. Furthermore, unlike adhesives, double-sided tape 51 does not require concern about curing time, making it easy to manufacture and convenient to use. The cap 30, whose joining surface 32 is firmly joined to the case 10 via the waterproof adhesive member 50 (double-sided tape 51), is substantially one-piece with the case 10 and can firmly support and clamp the external terminals 20.

[0049] In the power supply device described above, the battery block is housed in the case 10. At this time, the metal rod 21 of the external terminal 20 is inserted into the insertion hole 12 of the case 10, the protrusion 22 is exposed from the surface of the case, an O-ring 40 is placed in the groove 23, a waterproof adhesive member 50 is placed at the case joint 13, and then the cap 30 is attached to the protrusion 22. When the cap 30 is attached, the O-ring 40 in the groove 23 is sandwiched between the inner surface of the tubular portion 31, and the joint surface 32 is joined to the case 10 with the waterproof adhesive member 50, thereby sealing and connecting the external terminal 20 protruding from the insertion hole 12 in a waterproof structure.

[0050] The power supply device described above can be suitably used as a power supply device that can realize an effective waterproof structure with a simple structure while enabling electrical connection between a waterproof area and a non-waterproof area.

[0051] DESCRIPTION OF SYMBOLS 100, 800, 900... Power supply device 10... Case 11... Wall surface 12... Insertion hole 13... Case joint portion 20... External terminal 21... Metal rod 21A... Circular rod 21B... Non-circular rod 22... Protruding portion 22a... Side surface 23... Groove portion 25... Non-protruding portion 26... Female screw hole 27... Through hole 28... Female screw hole 30, 30A, 30B, 30C... Cap 31... Cylindrical portion 31X... Cylindrical portion 31a... Inner surface 32... Joint surface 33... Flange portion 40... O-ring 50... Waterproof adhesive member 51... Double-sided tape 810... Case 820... External terminal 830... Bus bar 840... O-ring 851... First nut 852... Ring member 910... Case 911... Fixing plate portion 920... External terminal 940...O-ring 950...Set screw

Claims

1. A power supply device comprising a battery block composed of battery cells and a case that houses the battery block, wherein the battery block has an external terminal that is a metal rod with its tip protruding outside the case, and a cap attached to the external terminal, wherein the external terminal is inserted into an insertion hole provided in the case and has a protruding portion that protrudes from the insertion hole, the cap has a tubular portion with a hollow portion through which the protruding portion is inserted, and a joint surface that is joined to the outer surface of the case, an O-ring placed in a groove provided on the side surface of the protruding portion and / or the inner surface of the tubular portion is interposed between the side surface of the protruding portion and the inner surface of the tubular portion, a waterproof adhesive member is interposed between the joint surface and the case, and the O-ring and the waterproof adhesive member seal each gap to create a waterproof structure.

2. A power supply device according to claim 1, wherein said cap has said cylindrical portion that is open at both ends.

3. A power supply device according to claim 1, wherein the joining surface is disposed on the bottom surface of the cap.

4. A power supply device according to claim 1, wherein the O-ring is disposed at a distance from the mating surface and is disposed in a twisted position relative to the mating surface.

5. A power supply device according to claim 1, wherein the groove is provided on a side surface of the protrusion.

6. A power supply device according to claim 1, wherein the outer shape of said protrusion is circular, and said tubular portion of said cap is a cylindrical portion.

7. A power supply device according to claim 6, wherein the cap has a flange portion connected to the cylindrical portion and protruding outward from the cylindrical portion, and the joint surface is on the bottom surface of the flange portion.

8. A power supply device according to any one of claims 1 to 7, wherein the waterproof adhesive member is a double-sided tape.

9. The power supply device according to claim 8, wherein the cap is made of resin or metal.

Images