Power source containing rechargeable batteries

• US 6,410,184 B1
• Filed: 01/27/2000
• Issued: 06/25/2002
• Est. Priority Date: 01/28/1999
• Status: Expired due to Term

• Current Assignee: Sanyo Electric Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Sanyo Electric Company Limited (Panasonic Holdings Corporation)
• Inventors: Horiuchi, Tatsuhito, Takasaki, Yoshiharu
• Primary Examiner(s): Kalafut, Stephan
• Assistant Examiner(s): ANTHONY, JULIAN
• Application Number:
  US09/492,184
• Time in Patent Office: 880 Days
• Field of Search: 429/149, 429/151, 429/153, 429/62, 429/163, 429/156, 429/159, 361/601, 361/728, 361/830
• US Class Current: 429/156
• CPC Class Codes: B60L 2260/56 Temperature prediction, e.g. for pre-cooling
• CPC Class Codes: B60L 58/30 for monitoring or controlling fuel cells
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 2200/106 PTC
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/522 Inorganic material
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

The power source holds a plurality of parallel oriented power modules in a holder-case. The holder-case is provided with cover-casings on both sides and intermediate-casings between them. Holder ribs project from the insides of cover-casings and from both sides of intermediate-casings for arranging power modules in a plurality of rows and retaining them in fixed positions. Cover-casings on both sides and intermediate-casings are joined to sandwich and hold the plurality of rows of power modules in fixed positions via the holder ribs.

Claims

1. A power source provided with a plurality of power modules, said power source comprising:

a holder case retaining said power modules in a parallel arrangement, said holder case comprising a first plastic cover having an inner side, a second plastic cover having an inner side, and a plastic intermediate member having opposite inner sides, said plastic intermediate member being located between said first plastic cover and said second plastic cover;

a plurality of holder ribs integrally formed on said inner side of said first plastic cover, said inner side of said second plastic cover, and said opposite inner sides of said plastic intermediate member, said holder ribs projecting so as to retain at least two of said power modules in a parallel arrangement, each of said holder ribs having an outer edge; and

a plurality of shock-absorbing gaskets attached to a corresponding number of said holder ribs, each of said shock-absorbing gaskets comprising an attachment groove extending along a length thereof,

wherein an outer edge of each of said corresponding number of said holder ribs is inserted into an attachment groove of one of said shock-absorbing gaskets, thereby attaching said shock-absorbing gaskets to said corresponding number of said holder ribs,

wherein said power modules are arranged in a plurality of rows, and

wherein at least one of said power modules is retained in a fixed position by said shock-absorbing gaskets that are attached to said holder ribs.

2. A power source as recited in claim 1, wherein said holder ribs are arranged in a plurality of rows, each of said holder ribs is formed in a single-piece construction.

3. A power source as recited in claim 2, wherein said holder case comprises a first end and a second end, and

wherein said holder ribs include a holder rib located at said first end of said holder case, a holder rib located at said second end of said holder case and a holder rib located between said first end and said second end of said holder case.

4. A power source as recited in claim 1, wherein the holder case has end-plates attached thereto, each of said end-plates comprising a pass bar connecting at least two of said power modules.

5. A power source as recited in claim 1, wherein at least one of said power modules is arranged between said plastic intermediate member and said first plastic cover, and wherein at least one of said power modules is arranged between said plastic intermediate member and said second plastic cover.

6. A power source as recited in claim 1, wherein at least one of said power modules comprises a straight line of rechargeable batteries.

7. A power source as recited in claim 6, wherein each of said rechargeable batteries is selected from a group consisting of nickel-hydrogen batteries, nickel-cadmium batteries, and lithium-ion batteries.

8. A power source as recited in claim 7, further comprising at least one temperature sensor,

wherein said at least one temperature sensor is fixed to a surface of one of said rechargeable batteries.

9. A power source as recited in claim 7, further comprising:

a plurality of temperature sensors; and

a plurality of temperature sensor leads,

wherein one of said temperature sensors and one of said temperature sensor leads are fixed to a surface of one of said rechargeable batteries.

10. A power source as recited in claim 7, wherein at least one of said power modules comprises one end having a positive electrode terminal, another end having a negative electrode terminal, and a straight line of electrically connected cylindrical rechargeable batteries,

wherein said straight line of electrically connected cylindrical rechargeable batteries has a first end and a second end,

wherein said positive electrode terminal is connected to said first end of said straight line of electrically connected cylindrical rechargeable batteries, and

wherein said negative electrode terminal is connected to said second end of said straight line of electrically connected cylindrical rechargeable batteries.

11. A power source as recited in claim 1, wherein at least one of said power modules comprises a capacitor.

12. A power source as recited in claim 1, wherein one holder rib comprises a plurality of retaining cavities,

wherein an outer surface of each of said power modules is similar to outer surfaces of the other power modules, and

wherein said retaining cavities have shapes that are complementary to said outer surfaces of said power modules, such that said retaining cavities retain a corresponding number of said power modules in fixed positions.

13. A power source as recited in claim 1, further comprising a plurality of shock-absorbing gaskets, each of said gaskets being attached to one of a first number of said holder ribs,

wherein a second number of said holder ribs, without shock-absorbing gaskets attached thereto, project higher than said first number of said holder ribs with shock-absorbing gaskets attached thereto,

wherein an outer edge of each of said second number of said holder ribs, are in contact, or are in close proximity to, one of a corresponding number of said power modules.

14. A power source as recited in claim 1, wherein each of said holder ribs comprises a number of retaining cavities capable of accommodating and retaining a corresponding number of said power modules in a parallel arrangement,

wherein said outer edges of said holder ribs are formed in a first wave-shape having peaks and valleys,

wherein each of said shock-absorbing gaskets is formed in a second wave-shape along a length thereof, and

wherein said second wave-shape is complementary with respect to said first wave-shape such that said shock-absorbing gaskets are attachable to said outer edges of said retaining cavities along said length thereof, respectively.

15. A power source as recited in claim 1, wherein an outer surface of each power module comprises a projection,

wherein said holder ribs comprise a plurality of bases and a plurality of cut-outs such that each base has one of said cut-outs located therein, and

wherein one of said projections are disposed within one of said cut-outs.

16. A power source as recited in claim 15, wherein each of said shock-absorbing gaskets comprises a plurality of resiliently deformable portions located along said length thereof such that said resiliently deformable portions are adjacent to said cut-outs, respectively.

17. A power source as recited in claim 16, wherein each of said resiliently deformable portions further comprises a slit.

18. A power source as recited in claim 1, wherein each shock-absorbing gasket comprises at least one projection for contacting and pressing against an outer surface of at least one of said power modules.

19. A power source as recited in claim 1, further comprising a plurality of temperature sensors selected from a group consisting of A, B and C,

wherein A comprises a plurality of temperature sensors mounted in said first plastic cover, said second plastic cover and said plastic intermediate member,

wherein B comprises a plurality of temperature sensors mounted in said first plastic cover and said second plastic cover,

wherein C comprises a plurality of temperature sensors mounted in said plastic intermediate member, and

wherein said temperature sensors are positioned on outer surfaces of said power modules.

20. A power source as recited in claim 19, wherein said temperature sensors are disposed so as to be parallel with said holder ribs.

21. A power source as recited in claim 20, wherein each of said holder ribs comprises a plurality of retaining cavities,

wherein each of said retaining cavities comprises a cut-out,

wherein a power module of said power modules is disposed in at least one of said retaining cavities, and

wherein at least one of said temperature sensors is disposed in one of said cut-outs.

22. A power source as recited in claim 21, wherein said holder ribs are disposed in rows, said retaining cavities and said cut-outs are disposed in columns, and

wherein said rows of said holder ribs are perpendicular to said columns of said retaining cavities and said cut-outs.

23. A power source as recited in claim 19, wherein said holder ribs are arranged in rows on each of said first plastic cover, said second plastic cover and said intermediate member,

wherein each of said first plastic cover, said second plastic cover and said intermediate member further comprises cut-outs disposed so as to separate each of said holder ribs, and

wherein said temperature sensors are disposed in said cut-outs.

24. A power source as recited in claim 19, wherein said holder ribs are arranged in rows on each of said first plastic cover, said second plastic cover and said intermediate member,

wherein each of said first plastic cover and said second plastic cover further comprises cut-outs disposed so as to separate each of said holder ribs, and

wherein said temperature sensors are disposed in said cut-outs.

25. A power source as recited in claim 19, wherein said holder ribs are arranged in rows on each of said first plastic cover, said second plastic cover and said intermediate member,

wherein said intermediate member further comprises cut-outs disposed so as to separate each of said holder ribs, and

wherein said temperature sensors are disposed in said cut-outs.

26. A power source as recited in claim 19, wherein each temperature sensor comprises at least two temperature sensing devices and a sensor lead,

wherein said temperature sensing devices of each temperature sensor are joined together in a straight-line configuration by said sensor lead of each temperature sensor.

27. A power source as recited in claim 26, wherein at least one of said temperature sensing devices is a PTC device.

28. A power source as recited in claim 26, wherein said power module comprise a plurality of rechargeable batteries connected in series, and

wherein at least one of said temperature sensors is disposed on each of said rechargeable batteries.

29. A power source as recited in claim 28, wherein said holder ribs comprise a plurality of bases and a plurality of cut-outs such that each base has one of said cut-outs located therein, and

wherein each of said shock-absorbing gaskets comprises a plurality of resiliently deformable portions located along said length thereof such that said resiliently deformable portions are adjacent to said cut-outs, respectively.

30. A power source as recited in claim 19, wherein said temperature sensors are disposed between said shock-absorbing gaskets and said power modules.

31. A power source as recited in claim 19, further comprising flexible material disposed in said holder case, said flexible material flexibly pushes said temperature sensors towards said power modules.

32. A power source as recited in claim 1, further comprising a plurality of temperature sensors mounted in said first plastic cover, said second plastic cover and said plastic intermediate member,

wherein said temperature sensors are positioned on outer surfaces of said power modules,

wherein said holder ribs comprise a plurality of bases and a plurality of cut-outs such that each base has one of said cut-outs located therein, and

wherein said temperature sensors are disposed between said cut-outs and said shock-absorbing gaskets.

33. A power source as recited in claim 1, further comprising a plurality of temperature sensors mounted in said first plastic cover and said second plastic cover,

wherein said temperature sensors are positioned on outer surfaces of said power modules,

wherein said holder ribs comprise a plurality of bases and a plurality of cut-outs such that each base has one of said cut-outs located therein, and

wherein said temperature sensors are disposed between said cut-outs and said shock-absorbing gaskets.

34. A power source as recited in claim 1, further comprising a plurality of temperature sensors mounted in said plastic intermediate member,

wherein said temperature sensors are positioned on outer surfaces of said power modules,

wherein said holder ribs comprise a plurality of bases and a plurality of cut-outs such that each base has one kof said cut-outs located therein, and

wherein said temperature sensors are disposed between said cut-outs and said shock-absorbing gaskets.

35. A power source case for use with a plurality of power modules, said power source case comprising:

a first cover having an inner side, a second cover having an inner side, and an intermediate member having opposite inner sides, said intermediate member being located between said first cover and said second cover;

at least one of said inner side of said first cover, said inner side of said second cover, said inner sides of said intermediate member comprises at least one holder rib integrally formed thereon, said at least one holder rib having an outer edge and projecting so as to retain at least two of the power modules in a parallel arrangement; and

at least one shock-absorbing gasket comprising an attachment groove extending along a length thereof,

wherein an outer edge of said at least one holder rib is inserted into said attachment groove thereby attaching said at least one shock-absorbing gasket to said at least one holder rib.

36. A power source case for use with a plurality of power modules, said power source case comprising:

a first cover having an inner side and a second cover having a inner side;

at least one of said inner side of said first cover and said inner side of said second cover comprises at least one holder rib integrally formed thereon, said at least one holder rib having an outer edge and projecting so as to retain at least two of the power modules in a parallel arrangement; and

at least one shock-absorbing gasket comprising an attachment groove extending along a length thereof,

wherein an outer edge of said at least one holder rib is inserted into said attachment groove thereby attaching said at least one shock-absorbing gasket to said at least one holder rib.