Abstract:
A battery module for containing a plurality of battery units, the battery module including first and second end plates facing each other; and a side plate, the side plate being for extending across a side of the battery units, and the side plate having a first end coupled to the first end plate and a second end coupled to the second end plate, wherein a work hardening unit is disposed at the second end of the side plate, the work hardening unit being hardened in such a way that the second end of the side plate is bent.

Description:
BACKGROUND 
     1. Field 
     Embodiments relate to a battery module and a battery pack including the same. 
     2. Description of the Related Art 
     In general, secondary batteries are chargeable and dischargeable unlike primary batteries, which are not chargeable. Secondary batteries may be used as energy sources for, e.g., mobile devices, electric vehicles, hybrid electric vehicles, electric bicycles, and uninterruptible power supply devices. Secondary batteries may be used in the form of a single battery or in the form of a battery module in which a plurality of batteries are electrically connected and packed as a single unit, according to the type of an external device in which the secondary batteries are to be used. 
     Small-sized devices such as mobile phones may be operated for a predetermined amount of time by using power output by and capacity of a single battery. On the other hand, battery modules may be usually used instead of a single battery in devices such as electric vehicles and hybrid electric vehicles consuming large amounts of power for a long time, since power output and capacity of a single battery may be insufficient. An output voltage and an output current of a battery module depends on the number of batteries accommodated therein. 
     In such battery modules, an assembly structure may be required to systematically bind a plurality of batteries to form a single assembly. The assembly structure may need to provide a coupling force sufficient for binding the plurality of batteries. Lithium ion batteries may be used as the secondary batteries. While lithium ion batteries may maintain a high performance even after repeated charging and discharging, a negative electrode thereof may expand due to lithium ions that are transferred during charging. 
     SUMMARY 
     Embodiments are directed to a battery module and a battery pack including the same, which represent advances over the related art. 
     It is a feature of an embodiment to provide a battery module capable of providing a coupling force that is sufficient to assemble a plurality of batteries in a single assembly. 
     It is another feature of an embodiment to provide a battery module for inhibiting deterioration of electrical characteristics by preventing expansion of batteries. 
     At least one of the above and other features and advantages may be realized by providing a battery module for containing a plurality of battery units, the battery module including first and second end plates facing each other; and a side plate, the side plate being for extending across a side of the battery units, and the side plate having a first end coupled to the first end plate and a second end coupled to the second end plate, wherein a work hardening unit is disposed at the second end of the side plate, the work hardening unit being hardened in such a way that the second end of the side plate is bent. 
     The work hardening unit may be adjacent to a coupling hole in the side plate and may contact a coupling member extending through the coupling hole. 
     The coupling hole may include a long coupling hole and a circular coupling hole, the circular coupling hole overlapping the long coupling hole by way of a portion of the side plate in which the long coupling hole and circular coupling hole are spaced apart from each other in a lengthwise direction being bent over itself into an overlapping condition. 
     The long coupling hole may have an oval shape with a major axis along the lengthwise direction of the side plate. 
     The circular coupling hole may have a substantially circular shape. 
     The side plate may include a first side plate that extends across a first surface of the battery units; and a second side plate that extends across a second surface of the battery units, the second surface being opposite to the first surface. 
     Each of the first and second end plates may include a base plate adjacent to the battery units; a first flange unit that is bent from the first side of the base plate in a direction away from the battery units; and a second flange unit that is bent from the second side of the base plate in a direction away from the battery units. 
     The first side plate may be coupled to the first flange units and the second side plate may be coupled to the second flange units. 
     At least one of the above and other features and advantages may also be realized by providing a battery module for containing a plurality of battery units, the battery module including first and second end plates facing each other; and a side plate, the side plate having a first end coupled to the first end plate and extending toward the second end plate, surrounding the second end plate, extending toward the first end plate, and being coupled to the first end plate via a second end of the side plate, wherein a work hardening unit is disposed at the second end of the side plate, the work hardening unit being hardened in such a way that the second end of the side plate is bent. 
     The work hardening unit may be adjacent to a coupling hole in the side plate and may contact a coupling member extending through the coupling hole. 
     The coupling hole may include a long coupling hole and a circular coupling hole, the circular coupling hole overlapping the long coupling hole by way of a portion of the side plate in which the long coupling hole and circular coupling hole are spaced apart from each other in a lengthwise direction being bent over itself into an overlapping condition. 
     The long coupling hole may have an oval shape with a major axis along the lengthwise direction of the side plate. 
     At least one of the above and other features and advantages may also be realized by providing a battery pack including a plurality of battery modules, each battery module including first and second end plates facing each other; a plurality of battery units disposed between the first and second end plates; and a side plate, the side plate being for extending across a side of the battery units and having a first end coupled to the first end plate and a second end coupled to the second end plate, wherein a work hardening unit is disposed at the second end of the side plate, the work hardening unit being hardened in such a way that the second end of the side plate is bent. 
     The work hardening unit may be adjacent to a coupling hole in the side plate and may contact a coupling member extending through the coupling hole. 
     The coupling hole may include a long coupling hole and a circular coupling hole, the circular coupling hole overlapping the long coupling hole by way of a portion of the side plate in which the long coupling hole and circular coupling hole are spaced apart from each other in a lengthwise direction being bent over itself into an overlapping condition. 
     The long coupling hole may have an oval shape with a major axis along the lengthwise direction of the side plate. 
     The circular coupling hole may have a substantially circular shape. 
     The side plate may include a first side plate that extends across a first surface of the battery units; and a second side plate that extends across a second surface of the battery units, the second surface being opposite to the first surface. 
     Each of the first and second end plates may include a base plate adjacent to the battery units; a first flange unit that is bent from the first side of the base plate in a direction away from the battery units; and a second flange unit that is bent from the second side of the base plate in a direction away from the battery units. 
     The first side plate may be coupled to the first flange units and the second side plate may be coupled to the second flange units. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features and advantages will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments with reference to the attached drawings, in which: 
         FIG. 1  illustrates an exploded perspective view of a battery module according to an embodiment; 
         FIG. 2  illustrates an assembled perspective view of the battery module of  FIG. 1 ; 
         FIGS. 3A and 3B  illustrate perspective views of a battery module showing formation of a work hardening unit; 
         FIG. 4  illustrates a perspective view of a battery pack according to an embodiment; 
         FIG. 5  illustrates an enlarged view of an end plate of  FIG. 4 ; 
         FIG. 6  illustrates a perspective view of a battery module according to another embodiment; 
         FIG. 7  illustrates a perspective view of a battery module according to yet another embodiment; and 
         FIG. 8  illustrates the battery module of  FIG. 7  from an end plate side. 
     
    
    
     DETAILED DESCRIPTION 
     Korean Patent Application No. 10-2009-0131805, filed on Dec. 28, 2009, in the Korean Intellectual Property Office, and entitled: “Battery Module and Battery Pack Comprising the Same,” is incorporated by reference herein in its entirety. 
     Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     In the drawing figures, the dimensions of layers and regions may be exaggerated for clarity of illustration. It will also be understood that when a layer or element is referred to as being “on” another element, it can be directly on the other element, or intervening elements may also be present. Further, it will be understood that when an element is referred to as being “under” another element, it can be directly under, and one or more intervening elements may also be present. In addition, it will also be understood that when an element is referred to as being “between” two elements, it can be the only layer between the two elements, or one or more intervening elements may also be present. Like reference numerals refer to like elements throughout. 
     The battery pack of an embodiment described herein may include a plurality of battery modules, each including a plurality of battery units that are arranged in a predetermined direction and electrically connected to each other. 
       FIG. 1  illustrates an exploded perspective view of a battery module  100 . Referring to  FIG. 1 , the battery module  100  may include a plurality of battery units  10  that are arranged in a row  15 , and plates  20 ,  30 ,  40 ,  51 , and  52  that surround the battery row  15 . In an implementation, the battery units  10  may be arranged in a single row in a predetermined direction. In another implementation, the battery module  100  may have a stacked structure in which the battery units  10  are arranged in multiple rows. 
     The battery units  10  may each be a secondary battery, e.g., a lithium ion battery. The battery units  10  may be any of various types of secondary batteries, e.g., cylindrical shape secondary batteries, square pillar shape secondary batteries, or polymer secondary batteries, but are not limited thereto. The battery units  10  may each include an electrode assembly (not shown), a case  11 , and electrode terminals  12 . Each electrode assembly (not shown) may include a positive electrode, a separator, and a negative electrode that are stacked and that may be wound. The cases  11  may accommodate the electrode assemblies; and the electrode terminals  12  may protrude out of the cases  11  in order to allow for an electrical connection between the electrode assemblies and an external circuit. The battery units  10  may be electrically connected to each other in series or in parallel via the electrode terminals  12 . For example, the electrode terminals  12  may be connected to each other via bus bars  18 . Each case  11  may include a safety vent  13 . The safety vents  13  may have a relatively low strength to fracture when an internal pressure in the cases  11  exceeds a predetermined threshold to thereby emit gas contained in the cases  11 . 
     The plates  51  and  52  may include first end plates  51  and second end plates  52  at ends of the battery row  15 . Each of the first and second end plates  51  and  52  may have a surface that is in a close contact with an outermost battery unit  10  of the battery row  15 . The first and second end plates  51  and  52  may bind the battery units  10  constituting the battery row  15  as a single unit, may inhibit volume expansion of the battery units  10  caused by charging and discharging operations, and may maintain resistance characteristics of the battery units  10 , so that deterioration of electrical characteristics of the battery may be beneficially inhibited. 
     The first and second end plates  51  and  52  may each include a base plate  61  and flange units  62 ,  63 ,  64 , and  65  that are bent at edges of the base plate  61 . The base plates  61  may each have an area that is sufficient to cover an external surface of the battery units  10 . 
     The flange units  62 ,  63 ,  64 , and  65  may be bent at edges of the base plates  61  in a direction away from the battery row  15 . In this regard, single flange units  63  and  64  may be formed by bending, without cutting, entire right, left, and lower edges of the base plates  61 . The flange units  62  and  65  may be separated from each other by cutting upper edges of the base plates  61  and bending the cut edges at different positions so that the bent portions have different heights. The flange units  62 ,  63 ,  64 , and  65  may function as a coupling unit to facilitate coupling of the first and second end plates  51  and  52  with other members and may be modified in various ways. In addition, the flange units  62 ,  63 ,  64 , and  65  may reinforce mechanical rigidity of the first and second end plates  51  and  52 . The flange units  62 ,  63 ,  64 , and  65  may include a plurality of binding holes. 
     The first and second end plates  51  and  52  may be connected to each other via plates  40 , which may be side plates. In other words, the side plates  40  may bind the first and second end plates  51  and  52  to each other. The side plates  40  may extend along sides of the battery row  15 . First ends of the side plates  40  may be coupled to the first end plate  51  and second ends of the side plates  40  may be coupled to the second end plate  52 . The side plates  40  may each have a strip shape that extends along the battery row  15 . The first ends of the side plates  40  may each have a first coupling hole  41  through which the side plates  40  and the flange unit  64 , bent at right and left edges of the first end plate  51 , may be, e.g., screw-coupled, to each other. For example, the side plates  40  and the flange unit  64  may be screw-coupled by overlapping the side plates  40  and the flange unit  64  and coupling them using coupling members  45  through the first coupling holes  41 . In an implementation, bolts may be inserted into the first coupling holes  41  and fastened with nuts. 
     The second ends of the side plates  40  may each have a second coupling hole  42  through which the side plates  40  and the flange unit  64 , that is bent at right and left edges of the second end plate  52 , may be, e.g., screw-coupled, to each other. The side plates  40  and the flange unit  64  may be screw-coupled by overlapping the side plates  40  and the flange unit  64  and coupling them using coupling members  45  through the second coupling holes  42 . In an implementation, bolts may be inserted into the second coupling holes  42  and fastened with nuts. 
     Work hardening units WH may be formed at the second ends of the side plates  40 , which may be adjacent to the second coupling holes  42 . For example, the work hardening units WH may have a roll shape at the second ends of the side plates  40 . The protruding work hardening units WH may contact the coupling members  45  when the coupling members  45  are inserted into the coupling holes  42 . Thus, coupling of the side plates  40  to the second end plate  52  may be strengthened since the work hardening units WH and the coupling members  45  are hooked together. The work hardening units WH may be formed by bending the second ends of the side plates  40  and overlapping the bent portions back onto the side plates  40 . The bent portions may have improved mechanical rigidity after they are processed by a work hardening process. Electrical characteristics of the battery units  10  may not be deteriorated since volume expansion of the battery units  10  may be inhibited due to a coupling force applied in the lengthwise direction of the side plates  40 . Further, the coupling force of the side plates  40  may be reinforced by forming the work hardening units WH at the second ends of the side plates  40 . 
     The side plates  40  may each have at least one heat dissipation hole  40   a . For example, a plurality of the heat dissipation holes  40   a  may be disposed along the lengthwise direction of the side plates  40  at equal intervals. Since the heat dissipation holes  40   a  may allow contact between the battery units  10  and external air, heat generated during operation of the battery units  10  may quickly be dissipated from the battery units  10 . 
     The plate  30  may be a lower plate under the battery row  15 . The lower plate  30  may be connected to lower portions of the first and second end plates  51  and  52  across a bottom of the battery row  15 . The lower plate  30  may include bending units  30   a  that are bent from side ends thereof to face each other. The lower plate  30  may support the total weight of the battery module  100  and bending rigidity thereof may be reinforced due to the bending units  30   a.    
     The lower plate  30  and the flange units  63  bent from the lower edges of the first and second end plates  51  and  52  may be, e.g., screw-coupled. The lower plate  30  and the flange units  63  may overlap each other and positions of coupling holes may correspond to each other and may then be screw-coupled using coupling members, e.g., bolts and nuts. 
     The plate  20  may be an upper plate disposed on the battery row  15 . The upper plate  20  may be connected to upper portions of the first and second end plates  51  and  52  across a top of the battery row  15 . The upper plate  20  may have bending units  21  that are bent from side ends thereof to face each other. The upper plate  20  may have openings  20   a  along a lengthwise direction of the upper plate  20  so as to correspond to the safety vents  13  of the battery units  10 . The upper plate  20  and the flange units  62 , bent from the upper edges of the first and second end plates  51  and  52 , may be, e.g., screw-coupled. The upper plate  20  and the flange units  62  may overlap each other and positions of coupling holes may correspond to each other, and may then be screw-coupled using coupling members, e.g., bolts and nuts. 
       FIGS. 3A and 3B  illustrate perspective views of a battery module showing the formation of the work hardening units WH of the side plates  40 . Referring to  FIG. 3A , the first end of one side plate  40  may be fixed to the first end plate  51  and may extend toward the second end plate  52 . A long coupling hole  42   a  and a circular coupling hole  42   b  may be disposed at the second end of the side plate  40  and spaced apart from each other by a predetermined distance in the lengthwise direction of the side plate  40 . 
     Referring to  FIGS. 3A and 3B , the second end of the side plate  40  may be bent into a roll shape to overlap the circular coupling hole  42   b  over the long coupling hole  42   a . Accordingly, the work hardening unit WH bent into a roll shape may be formed. The work hardening unit WH may have a flat-folded shape by applying compression, i.e., pressure, thereto. In this regard, a position of the circular coupling hole  42   b  overlapping the long coupling hole  42   a  may be changed along the lengthwise direction of the side plate  40  according to the bending of the side plate  40  and a manufacturing tolerance. Here, the long coupling hole  42   a  may have a shape extending in the lengthwise direction of the side plate  40  so that the circular coupling hole  42   b  may easily correspond to the long coupling hole  42   a.    
       FIG. 4  illustrates a perspective view of a battery pack  300  including a plurality of battery modules  100  as shown in  FIG. 3B . Referring to  FIG. 4 , the battery pack  300  may be an assembly of a plurality of battery modules  100  that are stacked in a vertical direction Z 1  and a horizontal direction Z 2 . The number of the battery modules  100  constituting the battery pack  300  may be determined in consideration of charging and discharging current and capacity; and may be electrically connected to each other in series or in parallel. 
     Adjacent battery modules  100  may be coupled to each other by coupling the end plates  51  and  52 , which are outermost layers of the battery module  100 .  FIG. 5  illustrates an enlarged view of the end plates  51  and  52  of  FIG. 4 . U, D, L, and R in brackets used herein respectively indicate relative positions of the battery modules  100 , i.e., upper (U), lower (D), left (L), and right (R). For example, the battery module  100  disposed at the upper left position may be indicated by  100 (U) and  100  (L). 
     The upper battery modules  100 (U) and the lower battery modules  100 (D) may be aligned in the vertical direction Z 1 . The lower flange units  63  may be disposed at lower edges of the upper battery modules  100 (U); and the upper flange units  65  may be disposed at upper edges of the lower battery modules  100 (D). The lower flange units  63  of the upper battery modules  100 (U) and the upper flange units  65  of the lower battery modules  100 (D) may be aligned to overlap each other and to align the coupling holes thereof. Then, the upper and lower battery modules  100 (U) and  100 (D) may be coupled using coupling members  154  through the coupling holes, e.g., by inserting bolts into the coupling holes and fastening the bolts with nuts. In this regard, the lower flange units  63  of the upper battery modules  100 (U) and the upper flange units  65  of the lower battery modules  100 (D) may have an interfacial contact therebetween on at least one portion. Via the interfacial contact between the lower flange units  63  and the upper flange units  65 , the weight of the upper battery modules  100 (U) may be sustained by the lower battery modules  100 (D). 
     The left battery modules  100 (L) and the right battery modules  100 (R) may be aligned in the horizontal direction Z 2 . The flange units  64  may be disposed at right edges of the left battery modules  100 (L) and left edges of the right battery modules  100 (R) and may be disposed to face each other. Here, the flange units  64  of the left battery modules  100 (L) and the right battery modules  100 (R) may overlap each other and coupling holes thereof may correspond to each other. Then, the left and right battery modules  100 (L) and  100 (R) may be coupled using coupling members  164  through the coupling holes, e.g., by inserting bolts into the coupling holes and fastened with nut. 
     As described above, a plurality of battery modules  100  that are aligned in the vertical direction Z 1  and the horizontal direction Z 2  may be assembled as a single battery pack  300  by coupling the end plates  51  and  52 . In this regard, the coupling of the end plates  51  and  52  may be conducted by using a mechanical coupling method using, e.g., bolts and nuts, or a welding method. 
       FIG. 6  illustrates a perspective view of a battery module according to another embodiment. Referring to  FIG. 6 , the first and second end plates  51  and  52  may be disposed at the outermost layers of the battery row  15 ; and side plates  140  that are disposed across sides of the battery row  15  may be coupled to the first and second end plates  51  and  52 . The side plates  140  may extend along sides of the battery row  15 . First ends of the side plates  140  may be coupled to the first end plate  51 ; and second ends of the side plates  140  may be coupled to the second end plate  52 . At least two side plates  140  may be disposed in parallel and spaced apart by a predetermined interval. The side plates  140  that are aligned in multi rows, i.e., in parallel, may bind the first and second end plates  51  and  52  by double coupling so that expansion of the battery row  15  that is interposed between the first and second end plates  51  and  52  may be inhibited. Thus, deterioration of electrical characteristics of the battery caused by volume expansion of the battery units  10  may be efficiently inhibited. 
     The side plates  140  may have first ends thereof coupled to the first end plate  51  and second ends thereof coupled to the second end plate  52  and may have a strip shape. Work hardening units WH that are bent into a roll shape may be formed at the second ends of the side plates  140 . The protruding work hardening units WH may contact the coupling members  45 ; and coupling strength between the work hardening units WH and the coupling members  45  may increase since the work hardening units WH and the coupling members  45  are hooked together. The work hardening units WH may be formed by bending the second ends of the side plates  140  and overlapping the bent portions onto the side plates  140 . The bent work hardening units WH may have high mechanical rigidity. Thus, coupling strength thereof to the side plates  140  may be improved. 
       FIG. 7  illustrates a perspective view of a battery module according to yet another embodiment.  FIG. 8  illustrates the battery module of  FIG. 7  from an end plate side. Referring to  FIGS. 7 and 8 , the first and second end plates  51  and  52  may be disposed at the outermost layers of the battery units  10  arranged in a row  15 . Then, the first and second end plates  51  and  52  and the battery row  15  may be bound by a side plate  240  that surround them. The second end plate  52  may have a left flange unit  64 L and a right flange unit  64 R at side ends thereof. For example, one end of the side plate  240  may be coupled to the left flange unit  64 L of the second end plate  52 ; and another end of the side plate  240  may be coupled to the right flange unit  64 R of the second end plate  52 . The side plate  240  may extend from the one end that is coupled to the left flange unit  64 L of the second end plate  52  toward the first end plate  51 , may surround the first end plate  51 , may extend toward the second end plate  52 , and may be coupled to the right flange unit  64 R of the second end plate  52 . 
     Here, a work hardening unit WH that is bent into a roll shape may be formed at the end of the side plate  240  that is coupled with the right flange unit  64 R. The protruding work hardening unit WH may contact one coupling member  45  that fixes the side plate  240 ; and the coupling strength of the side plate  240  may increase since the work hardening unit WH and the coupling member  45  are hooked each other. 
     Since the first and second end plates  51  and  52  and the battery row  15  may be coupled using the single side plate  240  in a single process, the number of parts and processes required to assemble the parts may be advantageously reduced. 
     According to the embodiments, when a plurality of batteries are coupled to each other to form a single battery module, portions providing binding or coupling forces may be bent and cured by a work hardening process to improve the coupling strength. Thus, mechanical rigidity of the entire battery module may be improved. Furthermore, since the batteries aligned in a row may be bound with a strong coupling force, volume expansion of the batteries may be inhibited and electrical characteristics may not be deteriorated. 
     In particular, in a battery pack including a plurality of secondary batteries, if each battery slightly expands, an entire volume of the battery pack may increase by about 5 to 10%. The battery pack of an embodiment may prevent serious deformation thereof; and electrical resistance of unit batteries may thereby be prevented from increasing. Thus, electrical characteristics of the battery pack may be maintained. 
     Exemplary embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. Accordingly, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.