Wire mounted battery module on vertical support frame

A battery pack and a vehicle including the same, the battery pack including a battery module including at least one battery cell; a support frame for supporting the battery module; and a support portion including a wire for supporting the battery module with respect to the support frame.

Korean Patent Application No. 10-2009-0128176, filed on Dec. 21, 2009, in the Korean Intellectual Property Office, and entitled: “Battery Pack and Vehicle Including Battery Pack,” is incorporated by reference herein in its entirety.

BACKGROUND

Embodiments relate to a battery pack and a vehicle including the battery pack.

2. Description of the Related Art

In general, unlike primary batteries, which are not chargeable, secondary batteries are chargeable and dischargeable. Secondary batteries are widely used in high-technology electronic devices, e.g., cellular phones, laptops, and camcorders, and are also used in vehicles.

Secondary batteries include an electrode assembly and an electrolyte. The electrode assembly includes a positive plate, a negative plate, and a separator. In a lithium ion secondary battery, the electrolyte includes lithium ions. The positive plate and the negative plate of the electrode assembly may each include an electrode tap protruding outside the electrode assembly.

The electrode assembly is accommodated inside a case, and an electrode terminal may be exposed outside the case. The electrode tap that protrudes outside of the electrode assembly may be electrically connected to the electrode terminal. The case may have, e.g., a cylindrical shape or an angular shape.

A plurality of unit secondary battery cells may be horizontally and/or vertically stacked so as to form a battery module. In addition, a plurality of battery modules may be vertically and/or horizontally stacked so as to form one battery pack.

SUMMARY

Embodiments are directed to a battery pack and a vehicle including the battery pack, which represents advances over the related art.

It is a feature of an embodiment to provide a battery pack formed by stacking a plurality of battery cells, wherein cooling efficiency of the battery pack is improved while a space for installing the battery cells is reduced.

At least one of the above and other features and advantages may be realized by providing a battery pack including a battery module including at least one battery cell; a support frame for supporting the battery module; and a support portion including a wire for supporting the battery module with respect to the support frame.

The battery module may be supported with respect to the support frame in such a way that the at least one battery cell contacts the support frame so as to be supported with respect to the support frame.

A plurality of the battery modules may be disposed on two surfaces of the support frame so as to be supported with respect to the support frame.

The support portion may include a first bracket on a first surface of the battery module opposite to a second surface of the battery module that contacts the support frame, the first bracket supporting the battery module with respect to one surface of the support frame; a second bracket on a first surface of the battery module opposite to a second surface of the battery module that contacts the support frame, the second bracket supporting the battery module with respect to another surface of the support frame; and a wire passing through the support frame and the first bracket and connected to the second bracket.

The wire may pass between battery cells of the battery module.

The first bracket or the second bracket may include an extension portion extending in a direction parallel to a direction in which battery cells are stacked so as to contact first surfaces of the battery cells opposite to second surfaces of the battery cells that contact the support frame; and a bent portion bent from the extension portion, the bent portion contacting a side surface of at least one of an uppermost battery cell of the battery module and a lowermost battery cell of the battery module.

The support portion may include a wire supporting member on the first bracket, the wire supporting member supporting the wire; and a tension adjuster on the second bracket, the tension adjuster supporting the wire and being configured to adjust tension of the wire.

The wire supporting member may be disposed on a first surface of the first bracket opposite to a second surface of the first bracket that contacts the battery module, and may support the wire.

The first bracket may include a support groove having an angular shape in the first surface thereof, wherein at least a portion of the wire support member extends into the support groove, and a through hole through the support groove, the wire passing through the through hole.

The tension adjuster may include a support bolt, the support bolt including a fixation portion at one side of the support bolt, the fixation portion supporting the wire and passing through the second bracket, and a screw portion at another side of the support bolt, the screw portion being exposed outside of a first surface of the second bracket opposite to a second surface of the second bracket that contacts the battery module and including a screw thread on an outer circumferential surface thereof; and a support nut coupled to the screw portion of the support bolt, the support nut contacting the first surface of the second bracket.

The fixation portion may have an angular shape, and the second bracket may include a support hole that is a though hole, the support hole having an angular shape, the fixation portion may extend into the support hole.

The battery pack may further include a circulation flow channel in the support frame, the circulation flow channel being configured to circulate cooling fluid.

The battery pack may further include a fluid tank connected to one end of the circulation flow channel, the fluid tank being configured to accommodate the cooling fluid; and a pump connected to another end of the circulation flow channel, the pump being configured to supply the cooling fluid of the fluid tank to the circulation flow channel.

The battery pack may further include a base for accommodating the fluid tank and the pump, the base supporting a lower portion of the support frame.

The battery module may be disposed on a single surface of the support frame.

The supporting portion may include a second bracket on a first surface of the battery module opposite to a second surface of the battery module that contacts the support frame, the second bracket supporting the battery module with respect to a first surface of the support frame; a wire passing through the support frame and connected to the second bracket; a wire supporting member on the support frame, the wire supporting member supporting the wire; and a tension adjuster on the second bracket, the tension adjuster supporting the wire and being configured to adjust tension of the wire.

The wire supporting member may be disposed on a second surface of the support frame, the second surface being opposite to the first surface of the support frame, and may support the wire.

The support frame may include a support groove having an angular shape in the second surface thereof, at least a portion of the wire support member may extend into the support groove, and the support groove may include a through hole extending through the support frame.

At least one of the above and other features and advantages may also be realized by providing a vehicle including a vehicle body; and the battery pack of an embodiment, the battery pack being installed in the vehicle body.

The battery pack may be quick drop installed in the vehicle body.

DETAILED DESCRIPTION

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. In addition, it will also be understood that when an element is referred to as being “between” two elements, it can be the only element between the two elements, or one or more intervening elements may also be present. Like reference numerals refer to like elements throughout.

FIG. 1illustrates a perspective view of a battery pack10according to an embodiment.FIG. 2illustrates a perspective view of the battery pack10ofFIG. 1where a cover300is removed.FIG. 3illustrates a cross-sectional view of battery modules100supported by wires402with respect to two surfaces of a support frame400, according to an embodiment.

The battery pack10may be formed by horizontally and/or vertically stacking the battery modules100. The battery module100may include at least one battery cell110that are stacked on top of each other. Heat may be generated from the battery cells110during charging and discharging. Thus, performance and the lifetime of the battery cells110may be reduced.

In particular, as the number of battery cells110is increased, an amount of heat generated therefrom may increase. Thus, in the battery pack10according to the present embodiment, the battery module100including the battery cells110may be supported with respect to the support frame400; and the heat generated from the battery cells110may be dissipated by, e.g., circulating cooling fluids in the support frame400.

The battery pack10may be installed in, e.g., an electrical vehicle1(seeFIG. 8) or a hybrid vehicle performing an electrical operation. In this case, the battery pack10may be installed in a limited space.

As many battery modules100as possible may be installed in a limited space of the battery pack10. If a large number of battery modules100are installed in the battery pack10, the battery pack10may have a high power output and longer lifetime.

In the battery pack10according the present embodiment, the battery cells110of the battery module100may be supported by the wires402with respect to the support frame400. Thus, a space for supporting the battery cells110on the support frame400may be reduced in the battery pack10. Accordingly, a size of the battery pack10may be reduced; and a large number of the battery cells110may be installed in a limited space.

The heat generated from the battery cells110may be effectively dissipated by more closely coupling the battery cells110to the support frame400in which cooling fluids are circulated. Thus, in the battery pack10according to the present embodiment, the battery cells110may be closely coupled to the support frame400. To achieve this, the battery cells110may be uniformly attached to the support frame400by using a supporting method using the wires402in the battery pack10.

Referring toFIGS. 1 through 3, the battery pack10may include the battery module100, the support frame400, and a support portion.

The battery module100may include at least one battery cell110. The support frame400may support the battery module100. The support portion may support the battery module100on the support frame400by using the wires402.

The battery cells110may be stacked in a first direction, e.g., a vertical direction so as to form the battery module100. The battery module100may be supported with respect to the support frame400in such a way that the battery cells110included in the battery module100may contact one surface or two surfaces of the support frame400and may be supported with respect to the surface or the two surfaces.

In this case, the battery cells110that are closely coupled to the support frame400may be cooled by cooling the support frame400. To achieve this, a circulation flow channel430may be disposed in the support frame400, as illustrated inFIG. 7. The heat generated from the battery cells110may be dissipated away from the battery pack10by circulating cooling fluids through the circulation flow channel430. Heat transferred from the battery cells110through the support frame400may be absorbed by the cooling fluids and may be dissipated away from the battery pack10.

Heat generated from the battery cells110may be effectively transferred to the support frame400by more closely coupling the battery cells110to the support frame400. Thus, in the battery pack10according to the present embodiment, the battery cells110may be uniformly attached to the support frame400.

The battery cells110may be supported with respect to the support frame400so as to contact the support frame400with a uniform pressure. To achieve this, as illustrated inFIG. 3, the battery module100may be supported with respect to the support frame400by disposing the wires402through spaces110abetween the battery cells110. An air channel for heat dissipation may be defined by the spaces110abetween the battery cells110.

The spaces110abetween the battery cells110may have a shape corresponding to upper and lower cases of the battery cells110(e.g., an uneven shape), which face each other. In an implementation, the spaces110abetween neighboring battery cells110may be formed by inserting a separate member having an uneven shape between the neighboring battery cells110.

The battery cells110may be stacked in a first direction, e.g., a vertical direction so as to form the battery module100. As illustrated inFIGS. 1 through 3, the battery cells110may each have an angular shape; but the embodiments are not limited thereto. In an implementation, the battery cells110may have various shapes, e.g., circular battery cells or pouch type battery cells.

The battery cells110may be, e.g., lithium-ion batteries; but the embodiments are not limited thereto. In an implementation, various batteries including, e.g., nickel-cadmium secondary batteries, nickel-hydrogen secondary batteries, and lithium batteries, may be used as the battery cells110.

As illustrated inFIG. 3, the battery module100may be disposed on and supported with respect to two surfaces of the support frame400. Thus, the battery cells110may be effectively accommodated in the limited space of the battery pack10. Therefore, as many battery cells110as possible may be accommodated in the limited space of the battery cells110.

In order to support the battery module100with respect to the support frame400, the support portion may include a first bracket410, a second bracket420, and the wires402.

The first bracket410may be disposed on a first surface of the battery module100opposite to a second surface of the battery module100that contacts the support frame400, so as to support the battery module100with respect to a first surface of the support frame400. The second bracket420may be disposed on a first surface of another battery module100opposite to a second surface of the other battery module100that contacts the support frame400, so as to support the battery module100with respect to a second surface of the support frame400.

In other words, a plurality of battery modules100may be disposed on two opposing, i.e., first and second, surfaces of the support frame400. The first bracket410may support the battery modules100with respect to one, i.e., the first, surface of the support frame400, e.g., a left surface of the support frame400ofFIG. 3. The second bracket420may support the battery modules100with respect to another, i.e., the second, surface of the support frame400, e.g., a right surface of the support frame400ofFIG. 3.

The battery cells110may include electrode terminals111that are exposed outside the battery cells110. The electrode terminals111of neighboring battery cells110may be electrically connected to each other by bus bars115.

The electrode terminals111may include positive and negative terminals. The neighboring battery cells110may be arranged so that the positive and negative terminals may be alternately arranged with respect to each other. The battery cells110may be connected in parallel, in series, or in both parallel and series.

Thus, the battery cells110may be sequentially connected to each other so as to form one battery module100. The connection method and the number of battery cells110may be determined in consideration of desired recharge or discharge capacities when the battery cells are designed.

The electrode terminals111may be disposed on first surfaces of the battery cells110opposite to second surfaces thereof that contact the support frame400. The first bracket410and the second bracket420may be disposed between the electrode terminals of the battery cells110.

The first bracket410and the second bracket420may contact all battery cells110of one of the battery modules100. In this case, the first bracket410and the second bracket420may more stably support all of the battery cells110of the battery module100.

The wires402may pass through the support frame400so as to be connected from the first bracket410to the second bracket420. To achieve this, through holes (not illustrated) through which the wires402pass may be formed in the support frame400. The wires402may pass between the battery cells110of the battery module100.

The wires402may pass between the battery cells110and through the support frame400so as to connect the first bracket410and the second bracket420. Thus, the battery module100supported by the first bracket410and the battery module100supported by the second bracket420may both be supported with respect to the support frame400.

In order for the first bracket410and the second bracket420to effectively support the battery cells110of the battery module100, the first bracket410may include an extension portion411and a bent portion412. In addition, the second bracket420may include an extension portion421and a bent portion422.

The extension portions411and421may extend in a direction corresponding to a direction in which the battery cells110are stacked so as to contact first surfaces of the battery cells110of the battery module100. The first surfaces of the battery cells110contacting the extension portions411and421may be opposite to second surfaces of the battery cells110that contact the support frame400. The bent portions412and422may be bent from the extension portions411and421, respectively, so as to support an uppermost battery cell110′ of the battery module100and a lowermost battery cell110″ of the battery module100.

The bent portions412and422may contact side surfaces of the uppermost battery cell110′ and the lowermost battery cell110″. In an implementation, the bent portions412and422may be formed by, e.g., bending ends of the extension portions411and421by 90 degrees, respectively.

The wires402may pass through the support frame400and between the battery cells110to support the battery modules100, thereby reducing a space for supporting the battery modules100with respect to the support frame400. Thus, a limited space for accommodating the battery cells110may be effectively achieved in the battery pack10.

In addition, the wires402may closely and uniformly attach the battery cells110to the support frame400in the middle of the battery pack10through the spaces between the battery cells110. Thus, heat generated from the battery cells110may be effectively transferred to the support frame400. According to the present embodiment, cooling efficiency may be improved while the battery cells110are accommodated in the limited space of the battery pack10.

FIG. 4illustrates a detailed diagram of the first bracket410and a wire supporting member401ofFIG. 1.FIG. 5illustrates a detailed diagram of the second bracket420and tension adjusters403and404ofFIG. 1.

Referring toFIGS. 4 and 5, the support portion may further include the wire supporting member401and the tension adjusters403and404. The wire402may be effectively supported with respect to the first bracket410and the second bracket420.

The wire supporting member401may be installed in the first bracket410to support the wire402. The tension adjusters403and404may be installed in the second bracket420to support the wire402and to adjust the tension of the wire402.

The wire402may surround an external surface of the wire supporting member401so that the wire supporting member401may support the wire402. The wire supporting member401may be disposed on a first surface of the first bracket410opposite to a second surface thereof that contacts the battery cells110so as to support the wire402.

To achieve this, a support groove410ainto which at least a portion of the wire supporting member401may be inserted may be disposed in the first surface of the first bracket410. In this case, a through hole410bthrough which the wire402passes may be disposed in the support groove410a.

The wire supporting member401may be prevented from sliding and rotating with respect to the first surface of the first bracket410by inserting the wire supporting member401into the support groove410a. Thus, when the tension adjusters403and404rotate in order to adjust the tension of the wire402, the wire supporting member401may be prevented from rotating together with the tension adjusters403and404, thus facilitating adjustment of the tension.

The wire supporting member401and the support groove410amay each have an angular shape. The angular shape of the wire supporting member401may correspond to the angular shape of the support groove410a. Accordingly, the wire supporting member401sliding and rotating with respect to the first surface of the first bracket410that contacts the wire supporting member401may be more effectively prevented.

The tension of the wire402may be adjusted by applying a pressure to the battery cells110so that the battery cells110are closely coupled. To achieve this, the support portion may include the tension adjusters403and404. In this case, the tension adjusters403and404may include a support bolt403and a support nut404.

One side of the support bolt403may be coupled to the wire402and another side of the support bolt403may be coupled to the support nut404. The support nut404may be screwed to the support bolt403so as to adjust the tension of the wires402.

The support bolt403may include a fixation portion403aat one side thereof and a screw portion403bat another side thereof. In addition, a support hole420ainto which a portion of the support bolt403may be inserted may be disposed in the second bracket420.

The fixation portion403amay support and/or fix the wire402. The fixation portion403amay pass through the second bracket420to be supported by the second bracket420. The support hole420ainto which the fixation portion403ais inserted may be disposed in the second bracket420.

The fixation portion403aand the support hole420amay each have an angular shape. The angular shape of the fixation portion403amay correspond to the angular shape of the support hole420a. Accordingly, sliding and rotating of the support bolt403with respect to the second bracket420may be more effectively prevented. Thus, the tension of the wire402may be effectively adjusted.

The screw portion403bmay extend from the fixation portion403aand may include screw threads on an outer circumferential surface thereof. The screw portion403bmay be exposed outside the first surface of the second bracket420. Thus, the screw portion403bmay be screwed to the support nut404.

The support nut404may be coupled to the screw portion403bof the support bolt403and may contact the first surface of the second bracket420.

As illustrated inFIG. 3, the battery modules100may be disposed on both surfaces of the support frame400to be supported; but the embodiments are not limited thereto. In an implementation, as illustrated inFIG. 6, the battery module100may be disposed on a single surface of a support frame400′.

FIG. 6illustrates a cross-sectional view of the battery modules100supported with respect to a single surface of the support frame400′ according to another embodiment.

InFIG. 6, the battery module100may be supported by wires402′ with respect to the support frame400′, like in the case ofFIG. 3. Like elements inFIGS. 3 and 6are denoted by like reference numerals; and thus repeated detailed descriptions thereof are omitted.

Referring toFIG. 6, the support portion may include a second bracket420, the wire402′, a wire supporting member401′, and tension adjusters403′ and404′.

The second bracket420may be disposed on a first surface of the battery module100opposite to a second surface that contacts the support frame400′ so that the battery module100may be supported with respect to a single surface of the support frame400′.

The wires402′ may pass through the support frame400′ to be connected to the second bracket420. The wires402′ may pass through the spaces110abetween the battery cells110so as to support the battery module100with respect to the support frame400.

The wire supporting member401′ may be installed in the support frame400′ so as to support the wires402′. In this case, the wire supporting member401′ may function similarly to the first bracket410ofFIG. 3.

The wire supporting member401′ may be disposed on a first surface of the support frame400′ opposite to a second surface of the support frame400′ that contacts the battery module100so as to support the wires402′. To achieve this, a support groove may be formed in the first surface of the support frame400′.

In order to prevent the wire supporting member401′ from rotating when the tension of the wires402′ is adjusted by the tension adjusters403′ and404′, the support groove and the wire supporting member401′ may each have an angular shape. The angular shape of the support groove may correspond to the angular shape of the wire supporting member401′.

The tension adjusters403′ and404′ may be installed in the second bracket420so as to support the wires402′ and to adjust the tension of the wires402′. The tension adjusters403′ and404′ may include a support bolt403′ and a support nut404′.

Thus, according to the present embodiment, cooling efficiency may be improved while the battery cells110are accommodated in the limited space of the battery pack10.

The battery pack10may further include a base200and a cover300. The support frame400may be installed and supported on the base200. The cover300may be detachably coupled to the base200and may accommodate the support frame400and the battery modules100therein.

FIG. 7illustrates a schematic cross-sectional view of a circulation flow channel430through which cooling fluids may be circulated in the support frame400, according to an embodiment.

The battery pack10may include a fluid tank510, a pump520, a connection flow channel530, and the circulation flow channel430. The fluid tank510, the pump520, and the connection flow channel530may be accommodated in the base200. The circulation flow channel430through which cooling fluids are circulated may be disposed in the support frame400.

The fluid tank510may be connected to one end of the circulation flow channel430and may accommodate cooling fluids therein. The pump520may be connected to another end of the circulation flow channel430and may supply the cooling fluids from the fluid tank510to the circulation flow channel430. The connection flow channel530may connect the fluid tank510and the pump520to each other.

A thermal management system (TMS) for dissipating heat generated by the battery module100may be installed in the base200. In an implementation, heat inside the cover300may be dissipated by the cooling fluids circulating through the circulation flow channel430in the support frame400, and thus a separate TMS may be omitted.

While the cooling fluids are circulating in the fluid tank510, the connection flow channel530, the pump520, and the circulation flow channel430, a temperature inside the battery pack10may be managed to correspond to an operation of the battery cells110. The cooling fluids may repeatedly circulate in the battery pack10.

The cooling fluids may include, e.g., air, water, ethanol, glycerin, and/or refrigerants; but the embodiments are not limited thereto. The cooling fluids may flow through the circulation flow channel430and may include various materials including, e.g., a phase change material (PCM).

Cooling fluids inside the fluid tank510may be managed to maintain a constant temperature in a predetermined place, e.g., an electricity station. The cooling fluids may be exchanged and/or added at the electricity station. To achieve this, the cover300may be detached from the base200so that the cooling fluids may be easily exchanged and/or added.

Thus, cooling efficiency of the battery pack10may be improved. The battery pack10installed using a quick drop method may be detached from a vehicle; and then the cooling fluids inside the fluid tank510may be exchanged and/or added from an external element.

FIG. 8illustrates a diagram of an electric vehicle1including the battery pack ofFIG. 1.

Referring toFIGS. 1 through 8, the battery pack10may be formed by vertically stacking the battery cells110to form the battery module100and then closely coupling a 2×3 configuration of battery modules100to a single surface or two surfaces of the support frame400.

Here, the circulation flow channel430may be disposed in the support frame400. While cooling fluids are circulating through the circulation flow channel430, heat generated by the battery cells110may be absorbed by the cooling fluids. To achieve this, the battery cells110may be uniformly attached to the support frame400, and thus the battery cells110may be effectively cooled.

The battery pack10may be installed in a limited space of a vehicle body30of the electric vehicle1. In the battery pack10according to the present embodiment, the battery module100may be supported by wires with respect to the support frame400so as to be installed in a small space.

The battery pack10may be installed in the vehicle body30by using a quick drop method in which the battery pack10is capable of being detached from the electric vehicle1. In addition, over time, the properties of the cooling fluids may deteriorate or an amount of the cooling fluids may be reduced. However, since the battery pack10according to the present embodiment may be installed in the electric vehicle1by using the quick drop method, the cooling fluids may be exchanged and/or added at a predetermined place, e.g., an electricity station. Accordingly, the cooling properties of the battery pack10may be improved.

As described above, according to the one or more of the above embodiments, cooling efficiency of a battery pack including a plurality of battery cells may be improved while a space for installing the battery cells may be reduced.