Patent Grant
10964495
The present disclosure relates to a switch device for opening an electrical circuit in response to entrance of a liquid as well as an electronic component and battery system incorporating the same. This application claims priority to Japanese Patent Application No. 2015-199813 filed on Oct. 7, 2015, the entire contents of which are hereby incorporated by reference.
In recent years, lithium ion secondary batteries have been incorporated in a large number of mobile phones and laptops, among other electronic appliances. Lithium ion secondary batteries have high energy densities and, to ensure the safety of users and electric appliances, are typically provided with several protective circuits incorporated in the battery pack for over-charging protection and over-discharging protection to interrupt the input and output of the battery pack under predetermined conditions. However, if a positive/negative electrode insulation fitting portion were to be corroded by being wet, there is a possibility that pressure from the interior of the battery might leak and a safety valve might malfunction to cause a fire.
PLT 1: Japanese Unexamined Patent Application Publication No. H11-144695
PLT 2: Japanese Unexamined Patent Application Publication No. 2000-162081
Some batteries have employed seals applied for detecting evidence of and providing a warning for exposure to water (for example, see PLT 1); however, battery use is not restricted, potentially creating a risk of a circuit malfunction caused, for example, by migration (degraded insulation) or short circuits due to a wet circuit substrate. Furthermore, a malfunction equivalent to that described above might occur in the case of leaking electrolyte solution accompanying a battery abnormality.
As a measure for wetting of electronic appliances with water, sensors for detecting liquids such as water have been provided which activate a protective circuit by transmitting a signal from the sensor when detecting water. For example, a water leak sensor having a detector constituted by a pair of electrodes disposed on an insulating substrate to face each other across a predetermined interval has been proposed (for example, see PLT 2). In this water leak sensor, when there is water between the electrodes of the detector, electricity leaking between terminals causes a signal to be input to a control circuit to control operation of the device. Because liquid has to enter into the detector to trigger operation, this water wetting sensor requires a configuration to actively draw water into the detector in a wet state; however, in states other than the wet state, in which activating the control circuit is unnecessary, the sensor must avoid improper activation so as to ensure reliability as a sensor.
In view of such conventional circumstances, an object of the present disclosure is to provide a switch device capable of safely opening an electrical circuit in response to an abnormality, such as wetting with water or liquid leaking from a battery, and an electronic component and battery system incorporating the same.
In order to solve the above problem, a switch device according to the present disclosure includes a first conductor connected to an external circuit and having a relatively high ionization tendency, and a second conductors arranged close to the first conductor and having a relatively low ionization tendency which is lower than that of the first conductor, a reaction part which electrically corrodes the first conductor being formed by a liquid between the first and second conductors.
Furthermore, an electronic component according to the present disclosure includes an external-connection terminal connected to an external circuit, and a conductor arranged close to the external-connection terminal and having a relatively low ionization tendency which is lower than that of the external-connection terminal, a reaction part which electrically corrodes the external-connection terminal being formed by a liquid retained between the external-connection terminal and the conductor.
Furthermore, a battery system according to the present disclosure includes a battery, and a conductor arranged close to a terminal of the battery and having a relatively low ionization tendency which is lower than that of the terminal, a reaction part being formed which electrically corrodes the terminal with a liquid retained between the terminal and the conductor.
According to the present disclosure, when liquid enters between the first and second conductors, electrical resistance in the first conductor increases due to electrical corrosive action, which decreases a current rating, it is thereby possible to safely open an electrical circuit.
Embodiments of a switch device according to the present disclosure as well as an electronic component and battery system incorporating the same will now be more particularly described with reference to the accompanying drawings. It should be noted that the present disclosure is not limited to the embodiments described below and it is a matter of course that various modifications can be added to the embodiments without departing from the scope of the present disclosure. Furthermore, the features illustrated in the drawings are illustrated schematically and are not intended to be drawn to scale. Actual dimensions should be determined in consideration of the following description. Moreover, those skilled in the art will appreciate that dimensional relations and proportions may be different among the drawings in some parts.
A switch device according to the present disclosure is incorporated into an external circuit such as a battery circuit and interrupts the external circuit in the case of a wet state such as submersion in water or liquid leaking. Referring to
The first conductor 2 serves as a connecting terminal for connecting to a terminal portion provided in the external circuit in which the switch device 1 is incorporated, and is, for example, formed in a substantially rectangular-plate shape; as the first conductor 2, it is possible to use a fuse element mounted between a pair of electrode terminals on an insulating substrate incorporated in the housing 6 of the switch device 1. Moreover, the first conductor 2 may be, for example, an electrode pattern formed on an insulating substrate incorporated in the housing 6 of the switch device 1, or a metal plate or lead wire, among others, may be used.
In the switch device 1, connecting ends of the first conductor 2 are led to the exterior of the housing 6 via a pair of electrode terminals to allow connection with a terminal portion of the external circuit. Furthermore, the switch device 1 allows current to flow through the first conductor 2 under normal conditions, and when the reaction part 5 comes into contact with a liquid, the reaction part 5 acts to cause blowout of the first conductor 2, thereby opening the external circuit.
The second conductor 3 is, for example, formed in a rectangular-plate shape as in the first conductor 2, and is arranged to oppose and be close to the first conductor 2. By arranging the first and second conductors 2, 3 close to each other, liquid entering the device interior collects to form the reaction part 5 which electrically corrodes the first conductor 2.
Furthermore, the second conductor 3 uses a material having a relatively lower ionization tendency than that of the first conductor 2. Thereby, when water enters between the first conductor 2 and the second conductor 3, the first conductor 2, being made of a base metal, becomes a positive electrode and is ionized (corroded); the first conductor 2 becomes narrower and/or pinholes are generated, thereby increasing electrical resistance of the first conductor 2, by which a rated current can be lowered.
The reaction part 5 irreversibly interrupts the first conductor 2 by coming into contact with a liquid entering the housing 6 and has a variety of configurations depending on the form of the first and second conductors 2, 3.
Referring now to
By arranging the fuse element 11 and the electrode 12 close to each other, a reaction part 5 is formed which electrically corrodes the fuse element 11 when a liquid exists therebetween. In this reaction part 5, when an abnormality occurs, such as wetting with water or liquid leaking from a battery, liquid collects between the fuse element 11 and the electrode 12, and the fuse element 11 is electrically corroded. This increases electrical resistance and decreases the rated current so that current flowing through the fuse element 11 causes the fuse element 11 to self-interrupt, by which an electrical circuit can be safely opened.
The fuse element 11 and electrode 12 are situated close to each such that water can enter, the distance therebetween is preferably 0.01 to 10 mm. Moreover, because reducing distance between the fuse element 11 and the electrode 12 increases electric field intensity and corrosive action as well as capillary action which promotes guidance of water between the fuse element 11 and the electrode 12, the distance between the fuse element 11 and the electrode 12 is more preferably 0.01 to 1 mm to more efficiently open the electrical circuit.
The fuse element 11 has a predetermined rated current and blows out when a current exceeding the rating flows therethrough. The fuse element 11 preferably contains, as a primary constituent, any one of aluminum, iron, nickel, tin, and lead. It should be noted that, herein, primary constituent means a component constituting 50 wt % or more of a total mass of a material.
The electrode 12 is arranged to face the central portion of one surface of the fuse element 11. It should be noted that the electrode 12 may be arranged so as to face central portions of both surfaces of the fuse element 11 to increase the amount by which the fuse element 11 is corroded.
Moreover, the electrode 12 is made of a metal having a lower ionization tendency than that of the fuse element and preferably contains, as a primary constituent, any one of gold, platinum, silver, copper, and palladium. Thereby, when water enters between the fuse element 11 and the electrode 12, the fuse element 11, which is made of a base metal, becomes a positive electrode and is ionized (corroded); the fuse element 11 becomes narrower and/or pinholes are generated and electrical resistance of the fuse element 11 increases, by which the rated current can be decreased.
As illustrated in
Thus, the switch device 1 constitutes an interrupting circuit including the fuse element 11 connected in series as a positive electrode to a direct-current power source and the electrode 12 connected as a negative electrode which has a lower ionization tendency than that of the fuse element 11 and which is close to the fuse element 11. Furthermore, as illustrated in
Furthermore, in the reaction part 5, one or a plurality of through holes, concaves, or convexes may be provided in one or both of the fuse element 11 and the electrode 12. As one example,
Likewise, providing a concave or a convex in the switch device 1 can preferentially guide liquid flowing into the housing 6 to the reaction part 5 as well as improve retention of the liquid; furthermore, increased amounts of liquid collected by the concave or the convex leads to increased contact areas of the fuse element 11 and electrode 12 with the liquid, thereby promoting electrical corrosion of the fuse element 11.
Referring to
Furthermore, the separator 14 preferably carries an electrolyte such as NaCl. This can improve electrical conductivity of water or electrolyte solution and promote corrosion.
Still further, the separator 14 may have a solubility property and dissolve in a liquid such as water or electrolyte solution. In this case, the separator 14 preferably has an electrically insulating property in addition to a solubility property. The separator 14 can thus ensure clearance between fuse element 11 and electrode 12 before entrance of the liquid and prevent short circuits, and, when the liquid enters, the separator 14 dissolves, thereby allowing a greater amount of liquid to be guided between the fuse element 11 and electrode 12 to promote electrical corrosion.
Examples of materials which are liquid-soluble include natural polymers such as agar and gelatin, semisynthetic polymers such as cellulose and starch, and synthetic polymers such as polyvinyl alcohol. These contract or dissolve on contact with a liquid. It should be noted that, because higher molecular weights strengthen a tendency of expanding rather than dissolving, it is preferable to adjust the degree of polymerization. Moreover, as a liquid-soluble material, in the case of using a water-soluble solid such as solidified sugar, the material dissolves or is reduced in volume by coming into contact with a liquid.
Furthermore, assuming an electrolyte solution such as of ethylene carbonate filling a battery cell as the liquid, in the case of a switch device for activating in response to leaking battery electrolyte solution, examples of the liquid-soluble material include ABS, polyacrylonitrile, polyvinylidene fluoride, saturated polyesters such as PET, PTT, and PEN, among others. In these liquid-soluble materials as well, because there are cases in which high molecular weights reduce dissolution rates and thus might reduce the reaction rate in the switch device 1, when giving priority to reaction rates, it is preferable to adjust the degree of polymerization.
Furthermore, the separator 14 disposed between the fuse element 11 and the electrodes 12 may be a water absorbing or hygroscopic electrical insulator. Moreover, an electrical insulator made of a sol, gel, or solid in which electrical conductivity is induced by the liquid may be arranged between the fuse element 11 and the electrode 12. Still further, an electrolyte constituted by a sol or gel may be used which induces electrical corrosion of the fuse element 11 when entering between the fuse element 11 and electrode 12.
Furthermore, the first and second conductors 2, 3 and reaction part 5 are not limited to the example configurations described above; for example, a plurality of fuse elements serving as the first conductor 2 may be arranged to overlap in parallel and an electrode serving as the second conductor 3 may be arranged between each of the fuse elements.
This reaction part 5 has a laminated structure in which three fuse elements 11 and three electrodes 12 are alternately laminated. Each of the fuse elements 11 and electrodes 12 are connected in respective parallel connections.
Arranging a plurality of the fuse elements 11 in this manner enables increases in current ratings and promotes electrical corrosion of the fuse element 11 when liquid enters between the fuse element 11 and electrode 12.
As illustrated in
In the reaction part 5, by each of the fuse elements 11 being faced on both sides by the electrodes 12, liquid is allowed between the electrodes 12 and both sides of each fuse element 11, thereby promoting electrical corrosion of the fuse elements 11.
Furthermore, the laminated structure of the reaction part 5 illustrated in
Still further, in the reaction part 5 illustrated in
In the switch device 1, a gap between the first and second conductors 2, 3 in a region in the vicinity of the reaction part 5 may be relatively narrower in comparison to that in other regions. For example, in the switch device 1, as illustrated in
An overlapping portion 12b which protrudes above the fuse element 11 is formed in a substantially central portion of the electrode 12. In the switch device 1, by arranging the overlapping portion 12b of the electrode 12 to oppose and be close to the fuse element 11, the reaction part 5 which collects liquid and electrically corrodes the fuse element 11.
The overlapping part 12b is supported by a support 15 provided, for example, in the housing 6, so as to oppose the fuse element 11 and is provided with a predetermined gap which allows entrance and retention of a liquid. The gap between the fuse element 11 and the overlapping part 12b is preferably 0.01 to 10 mm. Furthermore, because reducing distance between the fuse element 11 and the electrode 12 increases electric field intensity and corrosive action as well as capillary action which promotes guidance of water between the fuse element 11 and the electrode 12, it is more preferable that the gap between the fuse element 11 and the overlapping part 12b be 0.01 to 1 mm to more efficiently open the electrical circuit.
Moreover, in the switch device 1, as illustrated in
In the switch device 1, a plurality of surfaces of the first conductor 2 and the second conductor 3 may be in opposition. For example, in the switch device 1, as illustrated in
According to this reaction part 5, facing a plurality of surfaces of the fuse element 11 and electrode 12 with each other in the switch device 1 increases surface area on which liquid is held in comparison with configurations having only one surface facing another, and it is thereby possible to better promote blowout with electrical corrosion of the fuse element 11.
It should be noted that, in the reaction part 5, a curved portion or a bent portion may be formed in the second conductor 3 so as to surround three surfaces, or both side surfaces and a bottom surface, of the first conductor 2 so that a plurality of surfaces are in opposition.
In the switch device 1, the surface of at least one of the first and second conductors 2, 3 constituting the reaction section 5 may be coated with a liquid-soluble material which dissolves on contact with a liquid such as water or an electrolyte solution. For example, in an embodiment of the switch device 1 illustrated in
In the switch device 1, this can ensure clearance between the fuse element 11 and the electrode 12 before entrance of the liquid and prevent short circuits, and when the liquid enters, the coating layer 17 dissolves; a greater amount of liquid can thus be guided between the fuse element 11 and the electrode 12 to promote electrical corrosion.
As the liquid-soluble material constituting the coating layer 17, the same liquid-soluble materials as used to form the above-described separator 14 can be used.
Furthermore, the coating layer 17 made of the liquid-soluble material may be formed on one surface of the fuse element 11 facing the electrode 12 or may be formed on mutually facing surfaces of the fuse element 11 and the electrode 12.
Furthermore, in the switch device 1, a water repellent region may be provided in a location other than the reaction part 5, or in a location other than the reaction part 5 and the vicinity thereof. For example, in the switch device 1, as illustrated in
The water repellent treatment portion 18 can be formed using well-known methods such as applying a fluorine-based coating agent or a solder paste coating.
Thereby, the switch device 1 can guide liquid intruding onto the insulating substrate 16 to the reaction part 5 and the vicinity thereof, which is a non-water repellent region, thereby promoting blowout caused by electrical corrosion of the fuse element 11.
Further, in the switch device 1, a water-absorbing and heat-generating material 19 may be arranged in the vicinity of the reaction part 5. For example, a configuration of the switch device 1 illustrated in
In such a switch device 1, when liquid enters the vicinity of the reaction part 5, the water-absorbing and heat-generating material 19 absorbs moisture and generates heat which is transferred to the reaction part 5. Heat from the water-absorbing and heat-generating material 19 improves reaction efficiency in the reaction part 5, thus enabling rapid electrical corrosion and blowout of the fuse element 11.
As illustrated in
Next, the housing 6 of the switch device 1 will be described. The housing 6 of the switch device 1 can be formed from an electrically insulating material such as various engineering plastics, and ceramics, among other materials. By providing the switch device 1 with the housing 6, in addition to protecting the first and second conductors 2, 3 and the reaction part 5 from external mechanical disturbances, it is possible to prevent scattering of melted metal to the surroundings accompanying arc-discharge caused by blowout of the fuse element 11 used as the first conductor 2.
The housing 6 has a guiding inlet 7 for guiding liquid to the reaction part 5. In the switch device 1, liquid entering the reaction part 5 via the guiding inlet 7 of the housing 6 irreversibly interrupts the first conductor 2.
For example, as illustrated in
Moreover, the housing 6, as illustrated in
Furthermore, the housing 6 may be a tube shape and the guiding inlet 7 may be formed in any position and in any number.
It should be noted that the switch device 1 illustrated in
Furthermore, a discharging outlet may be formed in the housing 6 for discharging liquid entering via the guiding inlet 7.
It should be noted that the discharging outlet 8 is preferably formed to be smaller than the guiding inlet 7. By making the discharging outlet 8 relatively small, it is possible to prevent excessive discharge of liquid entering the housing 6 from causing a delay in the action of the reaction part 5 or in blowout of the first conductor 2.
Furthermore, the discharging outlet 8 is preferably provided at the same height as the reaction part 5 of the housing 6 or higher than the position of the reaction part 5. For example, as illustrated in
It should be noted that the guiding inlet 7 for guiding liquid and the discharging outlet 8 for discharging liquid may be any shape, for example, circular or rectangular. Furthermore, as illustrated in
In addition to providing the housing 6 with a slit-shaped guiding inlet 7 on the top surface 6a, the housing 6 may be provided with a guiding conduit 9 for guiding the liquid to the reaction part 5. As illustrated in
Furthermore, as illustrated in
It should be noted that, as illustrated in
Moreover, as illustrated in
Furthermore, in the switch device 1, as illustrated in
Forming the guiding inlet 7 in a position corresponding to the position of the reaction part 5 enables effective guidance of a large volume of liquid via the guiding inlet 7 to the first and second conductors 2, 3 and reaction part 5 in the switch device 1, thereby increasing efficiency of the reaction in the reaction part 5 and promoting blowout of the first conductor 2.
Furthermore, liquid may be led to the reaction part 5 in the switch device 1 by subjecting a location other than the reaction part 5 to a water repellent treatment. For example, as illustrated in
It is thereby possible to efficiently guide liquid entering via the guiding inlet 7 to the reaction part 5 in the switch device 1. In addition, by subjecting the guiding inlet 7 or the guiding conduit 9 to a water repellent treatment, in states other than wet states which should activate the switch device 1, small volumes of liquid can be repelled and not allowed to enter the housing 6, thereby preventing improper activation and ensuring reliability as a sensor.
Moreover, in the switch device 1, an interior wall of the housing 6 may be subjected to a water repellent treatment. By subjecting the interior wall of the housing 6 to a water repellent treatment, liquid entering the housing 6 can be efficiently guided to the reaction part 5 so that action of the reaction part 5 can occur rapidly.
Furthermore, as illustrated in
It should be noted that, in the switch device 1 as illustrated in
As illustrated in
Furthermore, assuming an electrolyte solution such as of ethylene carbonate filling a battery cell as the liquid, in the case of a switch device for activating in response to leaking battery electrolyte solution, examples of the water-soluble sealing material 22 include ABS, polyacrylonitrile, polyvinylidene fluoride, saturated polyesters such as PET, PTT, and PEN, among others. In these water-soluble materials as well, because there are cases in which high molecular weights reduce dissolution rates and thus might reduce the reaction time of the switch device 1, when giving priority to reaction rates, it is preferable to adjust the degree of polymerization.
By blocking the guiding inlet 7 or guiding conduit 9 with the water-soluble sealing material 22, in states other than wet states which should activate the switch device 1, small volumes of liquid can be repelled and not allowed to enter the housing 6, thereby preventing improper activation and ensuring reliability as a sensor.
Next, an example application of the present disclosure will be described. A switch device 1 according to the present disclosure may be incorporated in an electronic component such as an FET.
In the FET 30, in a normal state before liquid enters, the gate electrode 31 allows current to pass and is connected to connection terminals formed on any kind of circuit board. Then, in the FET 30, when liquid enters the housing 6, the gate electrode 31 is electrically corroded at the reaction part 5, thus interrupting the current. Therefore, the FET 30 can stop switching (deactivate functioning) by wetting with a liquid.
A power source schematically illustrated in
Furthermore, instead of the gate electrode 31, it is also possible to provide a drain electrode or a source electrode with the reaction part 5 in the same manner. In this case, the electrode becomes narrower due to electrical corrosion, thus decreasing current capacity and generating heat from current flowing therethrough; blowing out the electrode with this heating can be expected to achieve blowout more easily.
It should be noted that the switching element 1 may incorporate the FET 30 in the housing 6, and the gate electrode 31 may be blown out by liquid entering the housing 6. Alternatively, a housing of an electronic component such as that of the FET 30 may be used as the housing 6 of the switch device 1, and the guiding inlet 7 may be provided in the housing of this electronic component along with providing the reaction part 5 in the housing interior. Alternatively, the reaction part 5 may be formed outside of the housing of the electronic component by arranging the electrode 12 in the vicinity of the gate electrode 31 of the FET 30.
Furthermore, a switch device 1 according to the present disclosure may be incorporated in a battery cell.
The positive electrode 41 of the battery cell 40 allows current to flow under normal conditions, and electrical power is supplied to a circuit of any kind via electrode terminals of the battery holder. Then, when liquid enters the battery holder, such as in wetting with water or liquid leaking from a battery, the positive electrode 41 of the battery cell 40 is electrically corroded at the reaction part 5, thus interrupting the current. Thereby, the switch device 1 can stop current flow of the battery cell 40 when wetted with a liquid.
Furthermore, the switch device 1 may be constituted by a single cylindrical battery cell. A cylindrical battery cell 46, as illustrated in
The connecting portion 48c is overlapped at a predetermined clearance by a conductive projecting portion 47a projecting from the outer can 47 which is a negative electrode. In the battery cell 46, the reaction part 5 is thus formed by the connecting portion 48c, serving as the first conductor 2, and the projecting portion 47a, serving as the second conductor 3, overlapping the connecting portion 48c. It should be noted that the projecting portion 47a may be constituted by a portion of the external can 47 or may be constituted by using a conductor electrically connected to the external can 47.
In the battery cell 46, the center portion 48b serving as the positive electrode terminal portion allows current to flow under normal conditions, and electrical power is supplied to any of a variety of circuits. Then, when a liquid enters between the connecting portion 48c and the projecting portion 47a of the battery cell 46, such as in wetting with water or liquid leaking from a battery, the connecting portion 48c is electrically corroded at the reaction part 5, thus interrupting the current. Thereby, the switch device 1 can stop current flow of the battery cell 46 by wetting with a liquid.
As illustrated in
In the laminated battery cell 42, the positive electrode side lead wire 43 and a second negative electrode side lead wire 45 are connected to a charging device or to an electronic appliance and, under normal conditions, current is allowed to flow via the switch device 1, thus enabling charging/discharging. Then, in the laminated battery cell 42, when liquid enters the housing 6 of the switch device 1 such as when wet with water, the first conductor 2 blows out at the reaction part 5, and current is interrupted in the positive electrode side lead wire 43. Thereby, in the switch device 1, the charge/discharge path of the laminated battery cell 42 can be interrupted by being wet with liquid.
1 switch device, 2 first conductor, 3 second conductor, 5 reaction part, 6 housing, 7 guiding inlet, 8 discharging outlet, 9 guiding conduit, 11 fuse element, 11a first terminal, 11b second terminal, 12 electrode, 12a third terminal, 13 through hole, 14 separator, 15 support, 16 insulating substrate, 17 coating layer, 18 water repellent treatment portion, 19 water-absorbing and heat-generating material, 21 reservoir, 22 water-soluble sealing material, 30 FET, 31 gate electrode, 40 battery cell, 41 positive electrode, 42 laminated battery cell, 43 positive electrode side lead wire, 44 first negative electrode side lead wire, 45 second negative electrode side lead wire, 46 battery cell, 47 outer can, 47a projecting portion, 48 top cover, 48a outer edge portion, 48b center portion, 48c connecting portion
| Number | Date | Country | Kind |
|---|---|---|---|
| JP2015-199813 | Oct 2015 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2016/079595 | 10/5/2016 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/061454 | 4/13/2017 | WO | A |
| Number | Date | Country |
|---|---|---|
| 106463315 | Feb 2017 | CN |
| S55-93037 | Jul 1980 | JP |
| H11-144695 | May 1999 | JP |
| 2000-162081 | Jun 2000 | JP |
| 2009-037935 | Feb 2009 | JP |
| 2009-150806 | Jul 2009 | JP |
| 2015-228354 | Dec 2015 | JP |
| WO2015186687 | Dec 2015 | WO |
| Entry |
|---|
| WO2015/186687 English translation. Yoneda et al. Wipo. Dec. 10, 2015 (Year: 2015). |
| Nov. 29, 2016 Search Report issued in International Patent Application No. PCT/JP2016/079595. |
| Feb. 2, 2019 Office Action issued in Chinese Patent Application No. 201680055810.4. |
| Number | Date | Country | |
|---|---|---|---|
| 20180301302 A1 | Oct 2018 | US |
