Power source

Details Power source Power source

2000-02-16

2001-09-11

Luebke, Renee (Department: 2833)

Electrical connectors

With insulation other than conductor sheath

Plural-contact coupling part

C174S050000, C429S100000

Reexamination Certificate

active

06287150

ABSTRACT:

BACKGROUND OF THE INVENTION
This invention relates to a high current power source used primarily to power a drive motor for automobiles such as hybrid and electric automobiles.
A high current power source used to power an automobile drive motor achieves high output voltage by series connection of many battery cells. This is for the purpose of increasing drive motor output. A power source used for this type of application contains a large number of battery cells to increase output electrical power. For example, this type of power source is cited in Japanese Non-examined Patent Publication No. 10-270006 issued Oct. 9, 1998. The power source disclosed in this patent application contains a plurality of power modules arranged in rows in a holder-case, and each power module has a plurality of batteries lined up in a column. The holder-case has circular through-holes in both end walls for insertion of long, slender columns of power modules. Further, intermediate walls are provided parallel to the end walls to retain power modules in a stable manner, and these intermediate walls also have circular through-holes. Power modules are inserted through the holes in both end walls and through the holes in the intermediate walls to retain the power modules in fixed positions within the holder-case.
After inserting power modules into the holder-case, both ends of the holder-case are closed off with end-plates. The end-plates have pass bars to connect respective electrode terminals established at the ends of each power module. Each power module is mechanically attached and electrically connected to pass bars by setscrew attachment at the end-plates.
In this power source, non-circular shaped nuts are provided at the positive electrode end and at the negative electrode end respectively of each power module. Power modules are attached to the pass bars of both end-plates by fastening threaded setscrews through holes provides in the pass bars to mate with the non-circular shaped nuts at power module electrodes.
The outline of a positive electrode nut and the outline of a negative electrode nut are shaped differently. The two types of electrode nuts are configured such that alignment of one on top of the other allows the shape of neither nut to completely include the other. Further, retaining grooves with shapes corresponding to the outlines of the electrode nuts are provided in the end-plates. Electrode nuts are inserted into, and held by these retaining grooves. Retaining grooves for insertion and holding of positive electrode nuts are shaped differently than retaining grooves for insertion and holding of negative electrode nuts.
This type of configuration allows simple attachment of power modules to pass bars via setscrew termination. Insertion and retention of non-circular shaped nuts into retaining grooves and attachment via setscrews prevents rotation of power modules during the attachment process. As a result, not only is the power module attachment process simplified, but development of twists between power module battery cells is prevented. Further, the problem of power module mis-insertion is solved by shaping positive electrode nuts and their corresponding retaining grooves.
However, as shown in
FIG. 1
, since the retaining grooves
124
, which correspond to the outline shapes of the electrode nuts, are formed in the end-plates
103
, the power source cited in the prior art disclosure has the drawback of end-plates
103
with complicated shapes. Further, each power module
101
must be inserted into retaining grooves
124
in the end-plates
103
. Lining-up and inserting all of a large number, on the order of 20, power modules
101
is extremely difficult. In addition, since a large number of power modules
101
are retained in specified fixed positions, the system has the drawback of requiring very precise location of retaining grooves
124
in the end-plates
103
.
Consequently, the present invention provides a power source which simplifies end-plate shape and end-plate processing, eases the operation of power module insertion into the holder-case while preventing power module rotation, and prevents backwards insertion of power module positive and negative ends.
The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
SUMMARY OF THE INVENTION
The power source of the present invention holds a plurality of power modules disposed in a parallel fashion within a holder-case. Power modules are formed in a column of stick-shape by lining-up a plurality of batteries lengthwise and connecting them via connectors. Electrode terminals are provided at both ends of the stick-shaped power modules. The holder-case is split and configured with cover-casings disposed on both sides. The cover-casing on at least one side has holder ribs established, and the holder ribs are characterized by retaining cavities, which hold the power modules in place and prevent power module rotation.
In addition, holder ribs are established in the holder-case at positions corresponding to the electrode terminals provided at both ends of the power modules. Holder rib retaining cavities are characterized by retaining electrode terminals and preventing power module rotation during power module loading into the holder-case.
Electrode terminals provided at both ends of a power module comprise a positive electrode at one end and a negative electrode at the other end, and these positive and negative electrodes are formed in different shapes. Likewise, holder rib retaining cavities are characterized by their formation in different shapes corresponding to the electrode terminal shapes.
Further, retaining cavities which hold power module positive electrodes cannot hold power module negative electrodes, and retaining cavities which hold power module negative electrodes cannot hold power module positive electrodes. This configuration has the characteristic that backwards insertion of power modules is prevented.
A power source of the type described above has holder ribs established in the holder-case and has retaining cavities formed in the holder ribs to retain power module electrode terminals. This eliminates the need for retaining grooves in end-plates, which close off the holder-case, and allows simplification of end-plate shape. In addition, since the holder-case is of a split construction made up of cover-casings, retaining cavities established in the holder-case rather than in the end-plates allows simple retaining cavity formation without resorting to a complex mold.
Further, for insertion of power modules, simple placement of power modules within the split construction cover-casing suffices. The difficulty of lining-up and inserting power modules into retaining grooves provided in end-plates of prior art power sources is eliminated, and assembly can be performed extremely easily.
Once a power module has been placed in a cover-casing, that power module is reliably held by retaining cavities. Therefore, even when bolting adjacent power modules for connection, rotation of bolts and power modules can be prevented. Further, by making positive and negative electrode terminals in different shapes and by forming their corresponding retaining cavities in different shapes, backwards insertion of each power module can also be prevented.
Finally, since retaining cavities are established in the split construction cover-casings and are easily formed, a wide variety of electrode terminal shapes can also easily be accommodated.


REFERENCES:
patent: 5866276 (1999-02-01), Ogami et al.
patent: 5900332 (1999-05-01), Marukawa et al.
patent: 6152776 (2000-11-01), Ikeda et al.
patent: 10-270006 (1998-10-01), None

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