Patent Application
20240080980
The present invention relates to a power supply device.
Power supply devices including a number of secondary battery cells which are connected in series and in parallel are used as backup power sources for servers, home-, office- or factory-use power supply devices used as stationary power storage batteries, power sources for driving vehicles such, for example, as hybrid vehicles, electric vehicles, electric carts or electric scooters, and power sources for driving electric power-assisted bicycles or electric power tools. These power supply devices including a number of secondary battery cells connected in series and parallel pursue high capacity and high output power.
The power supply device with a number of secondary battery cells includes power semiconductor elements. such as charging/discharging field effect transistors (FETs). which are mounted on a circuit board to charge and discharge the secondary battery cells. A battery module including secondary battery cells connected in series and parallel often includes field effect transistors connected in parallel for controlling the high current charging and discharging to reduce a load on each transistor, as disclosed in, e.g., PTL 1.
In such circuit board, however, the high current input and output ports are often gathered in one place by using, for example, a terminal block due to structural restrictions of the module. Further, the arrangement of the FETs and wiring patterns on the circuit board is often designed under the structural restrictions. In this case, the FETs are arranged such that current is likely to concentrate on parts of the FETs may provide a problem that the current is unevenly distributed to the parts of the FETs and exceeds the current rating of elements, resulting in thermal destruction of the element.
An object of the present invention is to provide a power supply device suppressing uneven distribution of current even if semiconductor elements are mounted in a limited area on a circuit board.
A power supply device in an aspect of the present invention includes secondary battery cells, semiconductor elements connected to the secondary battery cells, and a circuit board on which the semiconductor elements are mounted. The circuit board includes a first terminal block and a second terminal block located away from the first terminal block. The first terminal block electrically connects the semiconductor elements to the secondary battery cells. The semiconductor elements include a first semiconductor element and a third semiconductor element that are disposed at s side of the first terminal block, and a second semiconductor element and a fourth semiconductor element that are disposed at a side of the second terminal block. the first semiconductor element and the third semiconductor element are connected in parallel to each other. The second semiconductor element and the fourth semiconductor element are connected in parallel to each other. The first semiconductor element and the second semiconductor element are connected in series to each other. A first current path connecting the first semiconductor element and the second semiconductor element in series to each other is longer than a second current path connecting the third semiconductor element and the fourth semiconductor element in series to each other. The first current path includes a first current impeding region configured to impede current flow. The second current path includes a second current impeding region configured to impede current flow. A second electrical resistance of the second current impeding region is higher than a first electrical resistance of the first current impeding region.
In the power supply device in an aspect of the present invention, the second current impeding region allowing current to flow more hardly is provided in the second current path which is shorter than the first current path and which allows current to flow more easily than the first current path. This configuration suppresses concentration of current and prevents the second semiconductor element and the fourth semiconductor element from being excessively heated, so that the semiconductor elements may be uniformly heated.
Exemplary embodiments of the present invention may also be described based on the following configurations.
In a power supply device according to an aspect of the present invention, in addition to the above-described structure, the first current impeding region and the second current impeding region may include thermal vias passing through the circuit board. The number of the thermal vias of the second current impeding region is larger than the number of the thermal vias of the first current impeding region.
In a power supply device according to another aspect of the present invention, in addition to any of the above-described structures, the semiconductor elements further may include: a fifth semiconductor element disposed at a side of the first terminal block; and a sixth semiconductor element disposed at a side of the second terminal block. The fifth semiconductor element may be connected in parallel to the first semiconductor element. The sixth semiconductor element may be connected in parallel to the second semiconductor element. A third current path connecting the fifth semiconductor element and the sixth semiconductor element in series to each other may be longer than the second current path. The third current path may include a third current impeding region configured to impede current flow. A third resistance of the third current impeding region may be equal to the first electrical resistance of the first current impeding region. In a power supply device according to still another aspect of the present invention, in addition to any of the above-described structures, the third current impeding region includes thermal vias passing through the circuit board. The number of the thermal vias of the third current impeding region may be equal to the number of the thermal vias of in the first current impeding region.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, the semiconductor elements further may include: a seventh semiconductor element disposed at a side of the first terminal block; and an eighth semiconductor element disposed at a side of the second terminal block. The seventh semiconductor element may be connected in parallel to the first semiconductor element. The eighth semiconductor element may be connected in parallel to the second semiconductor element. A fourth current path connecting the seventh semiconductor element and the eighth semiconductor element in series to each other may be equal in length to the second current path. The fourth current path may include a fourth current impeding region configured to impede current flow. A fourth electrical resistance of the fourth current impeding region may be equal to the second electrical resistance of the second current impeding region.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, the fourth current impeding region may include thermal vias passing through the circuit board. The number of the thermal vias of the fourth current impeding region may be equal to the number of the thermal vias of the second current impeding region.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, the first current impeding region and the second current impeding region may include thermal vias passing through the circuit board. Electrical resistances of the first current impeding region and the second current impeding region may be determined based on areas of openings of the thermal vias.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, the first semiconductor element and the third semiconductor element may be disposed closely to each other. The second semiconductor element and the fourth semiconductor element may be disposed closely to each other.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, the first terminal block and the second terminal block are through-holes.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, the semiconductor elements are field effect transistors.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, a source terminal of one field effect transistor out of field effect transistors constituting the first semiconductor element and the third semiconductor element may be closer to the first terminal block than a source terminal of another effect transistor out of the field effect transistors. The one field effect transistor may be closer to the first terminal block than the another effect transistor.
In a power supply device according to a further aspect of the present invention, in addition to any of the above-described structures, a source terminal of one field effect transistor out of field effect transistors constituting the second semiconductor element and the fourth semiconductor element may be closer to the second terminal block than a source terminal of another effect transistor out of the field effect transistors. The one field effect transistor may be closer to the second terminal block than the another effect transistor.
Hereinafter, exemplary embodiments of the present invention will be described based on the drawings. However, the exemplary embodiments shown hereinafter are examples for embodying the technical ideas of the present invention. Accordingly, the present invention is not limited to the following exemplary embodiments. Also, the present specification is not intended to limit the members recited in the claims to the members of the exemplary embodiments. Particularly, the dimensions, materials, shapes, and relative positions of the structural members written in the exemplary embodiments are not intended to limit the scope of the present invention to them unless otherwise specifically described to do so, but are merely explanation examples. The sizes and positional relations of the members shown in each figure are sometimes exaggerated to clarify the explanation. Further, in the following description, like names or like reference marks indicate like or identical members, and detailed explanation on them will appropriately be omitted. Further, each component constituting the present invention may be, in one aspect, such that plural components are configured using a same member to use a single member commonly as plural components, or may be, in another aspect on the contrary, such that plural members share implementation of one function of one member. Also, some contents described in a part of working examples or exemplary embodiments may be applicable to other examples or exemplary embodiments.
Also, the term “equal to” used in the present specification means not only exactly the same, but also approximately the same containing some margin of error.
Power supply devices according to exemplary embodiments may be used for various uses including, for example, backup power sources for servers, power sources equipped in electric-powered vehicles such, for example, as hybrid vehicles and electric vehicles to supply power to the driving motor, power sources for storing natural energy power generated by the solar power generation and wind-powered electricity generation, or power sources for storing the midnight electric power. Especially, power supply devices according to the exemplary embodiments may be used as power sources suitable to high-power, high-current uses. In the following examples, description will be made on a power supply device used as a backup power source for a server.
Power supply device 100 according to Exemplary Embodiment 1 of the present invention is shown in
Power supply device 100 shown in the circuit diagram of
Charging FETs 20C connected in parallel to one another and discharging FETs connected in parallel to one another are connected in series to one another through current impeding regions 50 provided between the parallelly connected charging FETs 20C and the parallelly connected discharging FETs 20D. Each current impeding region 50 has a predetermined electrical resistance. The electrical resistances of current impeding regions 50 are virtually indicated by electrical resistors 50R in the equivalent circuit shown in
Power supply device 100 according to the present exemplary embodiment is often configured under structural restrictions on the arrangement of charging/discharging FETs 20 mounted on circuit board 30 and circuit patterns of circuit board 30 to control the charging and discharging with high current. In this condition, such an arrangement that causes concentration of current on a part of charging/discharging FETs 20 may cause uneven distribution of current during charging or discharging, and excessively heat the part of charging/discharging FETs 20. Current impeding region 50 in each current path of circuit board 30 and adjusting the resistance of current impeding region 50, or adjusting the virtual electrical resistance 50R to increase the electrical resistance of a region on which current tends to concentrate, thereby suppressing the uneven distribution of current.
The secondary battery cells 10 are at least connected in series. A set of secondary battery cells 10 connected in series to one another may be connected in parallel to another set of secondary battery cells 10 connected in series to one another. An output of such a battery assembly that are constructed by secondary battery cells 10 containing series-connected secondary battery cells is obtained as an output from power supply device 100. Battery cells used as secondary battery cells 10 may be chargeable batteries such as lithium-ion batteries or nickel hydride batteries.
Charging/discharging FETs 20 are configured to control charging or discharging of secondary battery cells 10. The FET used as charging/discharging FET 20 may be any existing FET such as MOSFET.
The number of charging/discharging FETs 20 may be appropriately determined depending on the circuit board on which they are mounted. In the present exemplary embodiment, for example, first charging/discharging FET 21 to eighth charging/discharging FET 28 are mounted as charging/discharging FETs 20 on circuit board 30, which will be described later. In this example, each of first charging/discharging FET 21, third charging/discharging FET 23, fifth charging/discharging FET 25 and seventh charging/discharging FET 27 corresponds to the charging FET. Each of second charging/discharging FET 22, fourth charging/discharging FET 24, sixth charging/discharging FET 26 and eighth charging/discharging FET 28 corresponds to the discharging FET.
Circuit board 30 shown in
Circuit board 30 may have any shape. In the present exemplary embodiment, circuit board 30 substantially has a rectangular shape having short sides 30a and long sides 30b in plan view. As an example, short side 30a may have a length of about 6 cm and long side 30b may have a length of about 10 cm. However, the sizes of short sides 30a and long sides 30b may be appropriately determined depending on the components mounted on circuit board 30.
First terminal block 31 and second terminal block 32 are configured to input and output currents.
First charging/discharging FET 21 and third charging/discharging FET 23 are disposed at a side of the first terminal block 31 on circuit board 30, and second charging/discharging FET 22 and fourth charging/discharging FET 24 are disposed at a side of the second terminal block 32 on circuit board 30. The number of charging/discharging FETs 20 may be appropriately adjusted depending on the size of the circuit board. Accordingly, in the present exemplary embodiment, fifth charging/discharging FET 25 and seventh charging/discharging FET 27 are additionally disposed at a side of the first terminal block 31 on circuit board 30, and sixth charging/discharging FET 26 and eighth charging/discharging FET 28 are additionally disposed at a side of the second terminal block 32 on circuit board 30.
As an example, first charging/discharging FET 21, third charging/discharging FET 23, seventh charging/discharging FET 27, and fifth charging/discharging FET 25 are disposed at a side of the first terminal block 31 between first terminal block 31 and second terminal block 32 while deviating in a direction substantially along short side 30a of circuit board 30. First charging/discharging FET 21 and fifth charging/discharging FET 25 are disposed near the two long sides 30b of circuit board 30, respectively. Third charging/discharging FET 23 and seventh charging/discharging FET 27 are disposed between first charging/discharging FET 21 and fifth charging/discharging FET 25. In this example, third charging/discharging FET 23 is disposed at the side closer to first charging/discharging FET 21, and seventh charging/discharging FET 27 is disposed at the side closer to fifth charging/discharging FET 25.
First charging/discharging FET 21, third charging/discharging FET 23, seventh charging/discharging FET 27, and fifth charging/discharging FET 25 are disposed closely to one another. The FETs may be arranged in a direction to align on a straight line or may be arranged with an offset. For example, some charging/discharging FETs out of first charging/discharging FET 21, third charging/discharging FET 23, seventh charging/discharging FET 27 and fifth charging/discharging FET 25, having source terminals S closer to first terminal block 31 than other charging/discharging FETs may be disposed closer to first terminal block 31 than the other charging/discharging FETs.
In other words, first charging/discharging FET 21 and fifth charging/discharging FET 25 may be disposed closer to first terminal block 31 than third charging/discharging FET 23 and seventh charging/discharging FET 27. In this arrangement, the distance from each of the respective source terminals S of first charging/discharging FET 21 and fifth charging/discharging FET 25, which are located far apart from first terminal block 31, to first terminal block 31 may be reduced compared to the arrangement in which the charging/discharging FETs are disposed on a straight line. This configuration allows current to easily flow from first terminal block 31 to source terminals S of first charging/discharging FET 21 and fifth charging/discharging FET 25.
At a side of the second terminal block 32 on circuit board 30, second charging/discharging FET 22 is disposed at a position facing first charging/discharging FET 21, fourth charging/discharging FET 24 is disposed at a position facing third charging/discharging FET 23, sixth charging/discharging FET 26 is disposed at a position facing fifth charging/discharging FET 25, and eighth charging/discharging FET 28 is disposed corresponding to seventh charging/discharging FET 27.
Similarly to the first terminal block 31 side, second charging/discharging FET 22, fourth charging/discharging FET 24, eighth charging/discharging FET 28, and sixth charging/discharging FET 26 are disposed closely to one another. The FETs may be arranged in a direction to align on a straight line or may be arranged with an offset. Further, some charging FETs out of second charging/discharging FET 22, fourth charging/discharging FET 24, eighth charging/discharging FET 28 and sixth charging/discharging FET 26, having source terminals S closer to second terminal block 32 than other FETs may be disposed closer to second terminal block 32 than the other charging FETs.
On the other hand, as shown in
Regarding the connection of charging/discharging FETs 21 to 28, first charging/discharging FET 21, third charging/discharging FET 23, fifth charging/discharging FET 25, and seventh charging/discharging FET 27, which are disposed at the first terminal block 31 side on circuit board 30, are connected in parallel to one another. Similarly, second charging/discharging FET 22, fourth charging/discharging FET 24, sixth charging/discharging FET 26, and eighth charging/discharging FET 28, which are disposed at the second terminal block 32 side on circuit board 30, are connected in parallel to one another. Further, first charging/discharging FET 21 is connected in series to second charging/discharging FET 22, third charging/discharging FET 23 is connected in series to fourth charging/discharging FET 24, fifth charging/discharging FET 25 is connected in series to sixth charging/discharging FET 26, and seventh charging/discharging FET 27 is connected in series to eighth charging/discharging FET 28.
In the example described above in the present exemplary embodiment, charging/discharging FETs 21 to 28 are arranged such that their drain terminals face each other in planar view. However, the arrangement of the charging/discharging FETs according to the present exemplary embodiment may not be limited to the above-described embodiment. For example, the positions of charging FETs 20C and the positions of discharging FETs 20D may be reversed to each other. A circuit diagram of such example is shown in
Each of first current path 41 to fourth current path 44 includes a charging/discharging FET to aside of the first terminal block 31 on circuit board 30 and a charging/discharging FET at a side of the second terminal block 32 on circuit board 30 which are connected in series to each other as shown in
Regarding the positional relations of first current path 41 to fourth current path 44, first current path 41 and third current path 43 are disposed close to two long sides 30b of circuit board 30, respectively. Second current path 42 and fourth current path 44 are disposed between first current path 41 and third current path 43. In other words, first current path 41 and third current path 43 are located farther away from first terminal block 31 and second terminal block 32 than second current path 42 and fourth current path 44. This arrangement allows first current path 41 and third current path 43 to have the same length and longer than second current path 42. Fourth current path 44 has the same length as second current path 42.
In the structure in which terminal blocks are provided at locations respectively close to both short sides 30a of circuit board 30 and FETs are disposed closely to each of the terminal blocks as shown in
Each of current impeding regions 50 is configured to impede the flow of current by electrical resistance 50R indicating the resistance of the region. The number and sizes of current impeding regions 50 may be appropriately determined. In the present exemplary embodiments, first current impeding region 41 to fourth current impeding region 54 constitute current impeding regions 50. As shown in
In other words, each of second electrical resistance 52R of second current impeding region 52 and fourth electrical resistance 54R of fourth current impeding region 54 is higher than each of first electrical resistance 51R of first current impeding region 51 and third electrical resistance 53R of third current impeding region 53. This configuration allows currents to more easily flow in first current path 41 and third current path 43, which are the lower electrical resistance paths. As a result, although currents otherwise hardly flow in first current path 41 and third current path 43, more amounts of currents flow in first charging/discharging FET 21 and second charging/discharging FET 22 on first current path 41 and in fifth charging/discharging FET 25 and sixth charging/discharging FET 26 on third current path 43, thus suppressing the uneven distribution of current. Further, since the current concentration is suppressed, third charging/discharging FET 23, fourth charging/discharging FET 24, seventh charging/discharging FET 27 and eighth charging/discharging FET 28 are prevented from being excessively heated, thus suppressing the uneven heat generation so that heat generated at each charging/discharging FET becomes uniformly small.
To adjust first electrical resistance 51R to fourth electrical resistance 54R as described above, any arbitrary method may be used, including a method to change the width, thickness, or material of the conductive pattern in each current impeding region. In the present exemplary embodiment, an example of thermal vias 60 will be explained.
The number of thermal vias 60 in second current impeding region 52 is larger than the number of thermal vias 60 in first current impeding region 51. The increase of the number of thermal vias 60 in second current impeding region 52 may reduce the area of circuit board 30 in second current impeding region 52. In other words, the area of the region in which currents can flow is reduced, so that second electrical resistance 52R increases to cause currents to hardly flow in second current path 42.
Similarly, the number of thermal vias 60 in fourth current impeding region 54 is larger than the number of thermal vias 60 in third current impeding region 53. The increase of the number of thermal vias 60 in fourth current impeding region 54 may reduce the area of circuit board 30 in fourth current impeding region 54, so that fourth electrical resistance 54R may increase to cause currents to hardly flow in fourth current path 44. In this manner, the electrical resistance of each current path may be easily adjusted by the number of thermal vias 60 provided therein.
The number of thermal vias 60 may be appropriately determined depending on the size of the circuit board, the number and sizes of the mounted charging/discharging FETs, and the arrangement of the mounted components. In the present exemplary embodiment, for example, about 30 to 40 thermal vias 60 are formed in each of first current impeding region 51 and third current impeding region 53, and approximately 80 to 90 thermal vias 60 are formed in each of second current impeding region 52 and fourth current impeding region 54.
The thermal vias are usually used to improve the heat dissipation capability. In the present exemplary embodiment, however, a number of thermal vias are formed to increase the electrical resistance. In this manner, the electrical resistance may be adjusted by perforation, or by the simple machining, and such an advantageous effect can be obtained that the heat dissipation capability can be improved.
Thermal vias 60 in Embodiment 1 are formed to align in the vertical direction and in the lateral direction in planar view of
The hole diameters of thermal vias 60 in Embodiment 1 are approximately the same, the thermal vias of exemplary embodiments of the present invention may not be limited to the above-described embodiment. For example, the hole diameters of thermal vias 60C according to Exemplary Embodiment 3 are not the same as shown in
The increase of second electrical resistance 52R and fourth electrical resistance 54R allows more amounts of currents to flow in first current path 41 and third current path 43 in which otherwise currents hardly flow, thus suppressing the uneven distribution of current. In other words, the electrical resistance of each current path may be easily adjected by adjusting the areas of the openings of thermal vias 60C. Further, in the third exemplary embodiment, since the electrical resistance may be increased by merely increasing the hole diameter of each thermal via, it is possible to save the steps of forming a number of thermal vias.
Thermal via 60 has substantially a circular shape in Embodiment 1, the thermal vias according to exemplary embodiments of the present invention may not be limited to the above-described shape. For example, the shape of each thermal via may be substantially a rectangular shape like thermal vias 60D according to Exemplary Embodiment 4 shown in
A power supply device according to the present invention can be preferably used as a backup power supply device that can be equipped in the power modules of the computer servers. Also, the power supply device according to the present invention can be appropriately used as a backup power supply device for the wireless base stations of the mobile phones, a home-use storage battery, an industrial-use storage battery, a power source for the street light, an electric storage device combined with the solar cells, a backup power source for the traffic signals, or a power source for the electric vehicles such, for example, as the plug-in hybrid electric automobiles each being switchable between an EV driving mode and an HEV driving mode, the hybrid electric automobiles, and other electric automobiles.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-011501 | Jan 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/001891 | 1/20/2022 | WO |
