Patent Description:
Secondary batteries are rechargeable unlike non-rechargeable primary batteries. Secondary batteries may be used as energy sources of devices such as mobile devices, electric vehicles, hybrid electric vehicles, electric bicycles, and uninterruptible power supplies, and according to the types of external devices using secondary batteries, secondary batteries may be used as single battery cells or battery packs in which a plurality of battery cells are connected into a unit. <CIT> relates to a battery module in which battery cells are spaced apart by means of wedge shaped spacer bars.

The present invention provides a battery pack in accordance with claim <NUM>.

With respect to a number n of battery cells that one spacer unit extends across, a total number m of battery cells may be a multiple of the number n of battery cells that one spacer unit extends across.

The m number of battery cells arranged in the first direction may be arranged in two or more modules, and each of the modules may include k number of battery cells, in which k<m.

m may be a positive integer multiple of k such that m = p*k, in which p is a positive integer.

k may be a positive integer multiple of n such that k = p*n, in which p is a positive integer.

The battery pack may further include a pair of first end blocks respectively at a front end and a rear end of the m number of battery cells arranged in the first direction; and a second end block between adjacent modules of the two or more modules, wherein the first end blocks may each have substantially the same structure as the second end block.

Each of the spacer units may include the spacing bars at both ends thereof and at central portions between the ends thereof, in the first direction, the spacer units may be adjacent to each other in the first direction, spacing bars of the plurality of spacing bars at the ends of adjacent spacer units may overlap each other and are between adjacent ones of the battery cells, and spacing bars of the plurality of spacing bars at the central portions of a corresponding spacer unit may be between adjacent ones of the battery cells.

Spacing bars of the plurality of spacing bars at the ends of one spacer unit may have a thickness that is half of a thickness of the plurality of spacing bars at the central portion of the one spacer unit.

The connection bars may include a lateral connection bar extending in the first direction across lateral surfaces of the battery cells; and a bottom connection bar extending in the first direction across bottom surfaces of the battery cells.

The lateral connection bar may extend across outer surfaces of the plurality of spacing bars in a second direction intersecting with the first direction, and the bottom connection bar may extend across bottom surfaces of the plurality of spacing bars in a third direction intersecting with the first direction and the second direction.

The lateral connection bar and the bottom connection bar may be spaced apart from each other in a third direction that intersects with the first direction and intersects a second direction in which the lateral surfaces of the battery cells adjacent to each other face.

The lateral connection bar may face the lateral surfaces of the battery cells, and the bottom connection bar may face the bottom surfaces of the battery cells.

The bottom connection bar may support bottom surfaces of the battery cells.

The battery pack may further include side plates extending in the first direction and covering outer sides of the spacers; and a pair of first end blocks arranged at a front side of a foremost battery cell of the m number of battery cells arranged in the first direction and at a rear side of a rearmost battery cell of the m number of battery cells arranged in the first direction.

The side plate may cover lateral surfaces of the battery cells, the spacers being between the side plate and the lateral surfaces of the battery cells, and the first end blocks may cover large surfaces of the foremost battery cell of the m number of battery cells arranged in the first direction and the rearmost battery cell of the m number of battery cells arranged in the first direction.

The spacers and the side plates may be in pairs that face each other with the battery cells therebetween in a second direction intersecting with the first direction.

The m number of battery cells may be arranged in the first direction in two or more modules, in which k number of battery cells are in each module, and in which k<m, and the side plates may include two or more side plates coupled to each other on each module.

The first and second end blocks may each include hollow coupling holes at opposite ends thereof in a second direction intersecting with the first direction.

The first end blocks may each include coupling blocks at opposite ends thereof in in a second direction intersecting with the first direction, the side plate may include coupling ends at opposite ends thereof, and the coupling blocks may be aligned with the coupling ends.

The battery pack may further include bus bar holders on terminal surfaces of the battery cells, wherein the side plate includes a protruding piece that protrudes from a body of the side plate covering lateral surfaces of the battery cells toward the terminal surfaces and supports the terminal surfaces by supporting an edge of the bus bar holder.

Each of the spacer units may be the same size, and m may be a positive integer multiple of n such that m = p*n, in which p is a positive integer.

Features will be apparent to those of skill in the art by describing in detail exemplary embodiments with reference to the attached drawings in which:.

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 exemplary implementations 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 layer or element, it can be directly on the other layer or element, or intervening layers may also be present. In addition, it will also be understood that when a layer is referred to as being "between" two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present.

As used herein, the terms "or" and "and/or" are not exclusive terms and include any and all combinations of one or more of the associated listed items.

Hereinafter, a battery pack according to an embodiment will be described with reference to the accompanying drawings.

<FIG> is a perspective view of a battery pack according to an embodiment. <FIG> is an exploded perspective view of the battery pack of <FIG>. <FIG> is a perspective view of an assembly of battery cells and spacers. <FIG> is a perspective view of the battery cell of <FIG>. <FIG> are diagrams of the spacer of <FIG>, e.g., <FIG> is a diagram of the spacers assembled as seen on a large surface of the battery cell, <FIG> is a diagram of the spacers assembled as seen below bottom surfaces of the battery cells, and <FIG> is a perspective view of spacer units arranged continuously. <FIG> is a diagram of coupling between first and second end blocks and a side plate illustrated in <FIG>.

Referring to <FIG> and <FIG>, the battery pack includes m (e.g., <NUM>) battery cells <NUM> arranged in or along a first direction Z1, and spacers S each including a plurality of spacer units SU arranged in or along the first direction Z1. Each of the spacer units SU extends across or along n (e.g., <NUM>) battery cells <NUM>, in which n<m. Each of the spacer units SU includes a plurality of spacing bars SS (each of which being between adjacent battery cells), and connection bars SC (connecting the plurality of spacing bars SS to each other). In an implementation, the battery pack may include side plates <NUM> extending (e.g., lengthwise) in the first direction Z1 and covering outer sides of the spacers S, and a pair of first end blocks <NUM> at a front and a rear of the (e.g., row of) battery cells <NUM> in the first direction Z1.

Hereinafter, the battery pack of the present disclosure will be described in more detail.

Referring to <FIG> and <FIG>, the battery cell <NUM> includes a terminal surface <NUM> (including electrode terminals 11a and 11b thereon), a bottom surface <NUM> (opposite to the terminal surface <NUM>), large (main) surfaces <NUM> (connecting the terminal surface <NUM> to the bottom surface <NUM> and occupying a relatively large or first area), and lateral (side) surfaces <NUM> (connecting the terminal surface <NUM> to the bottom surface <NUM> and occupying a relatively small second area). The second area is smaller than the first area. In an implementation, the electrode terminals 11a and 11b may be a pair of first and second electrode terminals 11a and 11b having different polarities, and the first and second electrode terminals 11a and 11b may be arranged or spaced apart along a second direction Z2 intersecting with the first direction Z1 (in which the battery cells <NUM> are arranged). In an implementation, any one of the first and second electrode terminals 11a and 11b may be omitted, in which case, a portion of an outer surface of the battery cell <NUM> may function as the omitted one of the electrode terminals 11a and 11b.

The large surfaces <NUM> of the battery cell <NUM> are a pair of large surfaces <NUM> that are at both opposite sides of the battery cell <NUM> in the first direction Z1. The battery cells <NUM> are arranged in or along the first direction Z1, and the battery cells <NUM> adjacent to each other have the large surfaces <NUM> thereof facing each other. Among the m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1, the foremost and rearmost large surfaces <NUM> of the battery cells <NUM> arranged in the first direction Z1 (e.g., battery cells <NUM> at ends of the row of m battery cells <NUM>) may be covered by a pair of the first end blocks <NUM>, respectively.

The lateral surfaces <NUM> of the battery cell <NUM> are a pair of lateral surfaces <NUM> at both opposite sides of the battery cell <NUM> in the second direction Z2. The spacer S secures a gap between the battery cells <NUM> adjacent to each other and the side plate <NUM> may cover an outer side of the spacer S, and may be sequentially arranged on the lateral surfaces <NUM>. The spacers S and preferably also the side plates <NUM> are arranged in pairs to face each other with the battery cells <NUM> therebetween in the second direction Z2, and are fixed on the lateral surfaces <NUM> at both sides of the battery cells <NUM>.

Referring to <FIG> and <FIG>, the spacer S includes the plurality of spacer units SU arranged in or along the first direction Z1. In an implementation, the plurality of spacer units SU may have substantially the same shape, the plurality of spacer units SU having substantially the same shape may be continuously arranged in the first direction Z1, and accordingly, the spacer S may extend entirely across or along the plurality of battery cells <NUM> arranged in the first direction Z1 (e.g., each of the battery cells <NUM> may include a spacer unit SU thereon).

A number m of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) are arranged in the first direction Z1, and each of the spacer units SU extends across n number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) (in which n<m). With respect to the number n (e.g., <NUM>) of battery cells <NUM> that one spacer unit SU extends across in the first direction Z1, the total number m (e.g., <NUM>) of battery cells <NUM> may be a multiple of the number n (e.g., <NUM>) of battery cells <NUM> that one spacer unit SU extends across. In an implementation, m may be p*n, in which p is a positive integer. In an implementation, the plurality of spacer units SU that each extend across the number n (e.g., <NUM>) of battery cells <NUM> may be consecutively arranged in the first direction Z1 to form the spacer S that extends across the total number m (e.g., <NUM>) of battery cells <NUM>.

In an implementation, in the case where the battery pack according to an embodiment includes <NUM> battery cells <NUM>, the spacer S extending across all the <NUM> battery cells <NUM> may be implemented by continuously arranging <NUM> spacer units SU, and each spacer unit SU may extend across or along <NUM> battery cells <NUM> in the first direction Z1.

The battery pack according to the present disclosure may be configured to be expandable in a module BM. The battery pack according to an embodiment may include m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1. In an implementation, the m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) may be arranged in two or more modules BM, in which k (k<m) number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) are in each module BM. In this case, the spacer S extending entirely across the k number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) constituting one module BM may be implemented as a continuous arrangement of a plurality of spacer units SU each extending across the n battery cells <NUM> (e.g., <NUM> battery cells <NUM>), and the number k of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) constituting one module BM may be a multiple of the number n of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) that one spacer unit SU extends across.

In an implementation, the battery pack according to an embodiment may include a total of <NUM> battery cells <NUM>, in two modules BM each including <NUM> battery cells <NUM>, and each of the modules BM that includes the <NUM> battery cells <NUM> may include three spacer units SU each extending across four battery cells <NUM> such that the three spacers S extend across the <NUM> battery cells <NUM> included in one module BM.

Referring to <FIG> and <FIG>, a structure of the spacer unit SU will be described in more detail. The spacer unit SU includes a plurality of spacing bars SS between adjacent battery cells <NUM>, and a plurality of connection bars SC connecting the plurality of spacing bars SS to each other. The spacing bars SS are arranged in front and rear of each of the battery cells <NUM> in the first direction Z1, to secure a gap between the adjacent battery cells <NUM>. The spacing bar SS provide a gap that may accommodate swelling of the battery cells <NUM> during charging and discharging, and may accommodate volume expansion caused by the swelling between the adjacent battery cells <NUM>, thereby reducing or preventing excessive stress from being generated between the adjacent battery cells <NUM> and reducing or preventing structural binding of the battery pack along an arrangement direction of the battery cells <NUM> from deteriorating due to accumulation of the excessive stress.

The spacing bar SS are between the large surfaces <NUM> of the battery cells <NUM> adjacent to each other in the first direction Z1, and may protrude from a position corresponding to the lateral surfaces <NUM> of the battery cells <NUM> in the second direction Z2. A plurality of spacing bars SS are arranged or spaced apart in the first direction Z1 to be between the battery cells <NUM> adjacent to each other in the first direction Z1. Hence each of the spacing bars SS extends lengthwise in a third direction Z3 intersecting with the first direction Z1 and the second direction Z2, and may be between the adjacent battery cells <NUM> over or along a total height of the large surface <NUM> of the battery cell <NUM> (from the terminal surface <NUM> to the bottom surface <NUM> of the battery cell <NUM> in the third direction Z3).

The spacer unit SU further includes connection bars SC extending across the plurality of spacing bars SS arranged in the first direction Z1 to connect the plurality of spacing bars SS to each other. The connection bars SC extend (e.g., lengthwise) in the first direction Z1, connect the plurality of spacing bars SS arranged in the first direction Z1 to constitute or form the spacer unit SU as one part, and connect the plurality of spacing bars SS each between the large surfaces <NUM> of the battery cells <NUM> to secure rigidity of the entire battery pack in the first direction Z1. A battery pack includes m number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1, and a slip could occur between the battery cells <NUM> adjacent to each other, thereby causing warpage or distortion of the battery pack in the first direction Z1. Therefore the connection bars SC connect the plurality of spacing bars SS each between the large surfaces <NUM> of the battery cells <NUM> to each other, and thus, the rigidity of the entire battery pack in the first direction Z1 may be secured.

The connection bar SC may include a lateral connection bar SC1 extending across or along the lateral surfaces <NUM> of the battery cells <NUM> and a bottom connection bar SC2 extending across or along the bottom surfaces <NUM> of the battery cells <NUM>. In this case, the lateral connection bar SC1 may extend across (e.g., in parallel with) the lateral surfaces <NUM> of the plurality of battery cells <NUM> arranged in the first direction Z1 to hold an assembly position of the battery cells <NUM> in the second direction Z2, and the bottom connection bar SC2 may extend across (e.g., in parallel with) the bottom surfaces <NUM> of the plurality of battery cells <NUM> arranged in the first direction Z1 to hold an assembly position of the battery cells <NUM> in the third direction Z3. In an implementation, the lateral connection bar SC1 may support the lateral surfaces <NUM> of the battery cells <NUM>, and the bottom connection bar SC2 may support the bottom surfaces <NUM> of the battery cells <NUM>. In an implementation, the lateral connection bar SC1 and the bottom connection bar SC2 may support the lateral surfaces <NUM> and the bottom surfaces <NUM> of the battery cells <NUM> and hold the assembly positions of the battery cells <NUM> in the second direction Z2 and the third direction Z3, and an assembly position of the spacer S may be held on the battery cells <NUM> through the lateral connection bar SC1 and the bottom connection bar SC2 supported on the lateral surfaces <NUM> and the bottom surfaces <NUM> of the battery cells <NUM>.

The lateral connection bar SC1 and the bottom connection bar SC2 may contribute to the rigidity of the battery pack in the first direction Z1, e.g., the lateral connection bar SC1 and the bottom connection bar SC2 at positions spaced apart from each other in the third direction Z3 may connect the spacing bars SS to each other, thereby strengthening mutual binding between the spacing bars SS and effectively reinforcing the rigidity of the battery pack in the first direction Z1. In an implementation, the bottom connection bar SC2 may extend in the first direction Z1 while supporting the bottom surfaces <NUM> of the plurality of battery cells <NUM> arranged in the first direction Z1, and may effectively help prevent the slip between the battery cells adjacent to each other and may contribute to the rigidity of the battery pack in the first direction Z1.

The lateral connection bar SC1 and the bottom connection bar SC2 may be arranged in different orientations. In an implementation, the lateral connection bar SC1 may face the lateral surfaces <NUM> of the battery cells <NUM>, while the bottom connection bar SC2 may face the bottom surfaces <NUM> of the battery cells <NUM>. In an implementation, the lateral connection bar SC1 and the bottom connection bar SC2 may be coupled to different portions of the spacing bars SS, e.g., the lateral connection bar SC1 may extend across outer surfaces of the spacing bars SS (e.g., surfaces facing in the second direction Z2), and the bottom connection bar SC2 may extend across bottom surfaces <NUM> of the spacing bars SS (e.g., surfaces facing in the third direction Z3). In an implementation, the lateral connection bar SC1 may be connected to the outer surfaces of the spacing bars SS in the second direction Z2, e.g., may be connected to protruding surfaces SP protruding toward the outside from the outer surfaces of the spacing bars SS. In this case, the lateral connection bar SC1 may extend across the protruding surfaces SP of the spacing bars SS arranged in the first direction Z1, and may bind the spacing bars SS to each other.

The spacing bars SS are arranged in or at a front side and a rear side of each of the m number battery cells <NUM> (e.g., <NUM> battery cells <NUM>). In fact, one spacing bar SS is arranged in or at a front side and a rear side of each battery cell <NUM>, and one spacing bar SS is between the battery cells <NUM> adjacent to each other. In an implementation, as illustrated in <FIG>, to implement the spacer S extending across the m number battery cells <NUM> (e.g., <NUM> battery cells <NUM>) in the first direction Z1, two spacer units SU adjacent to each other in the first direction Z1 may configure or provide two spacing bars SS arranged to overlap or be in close contact with each other between a specific pair of battery cells <NUM>. In an implementation, the two spacing bars SS (e.g., together) may be between the specific pair of battery cells <NUM>. In an implementation, in the case where the plurality of spacer units SU are continuously arranged in the first direction Z1, spacing bars SS1 at adjacent, e.g., facing, ends of the spacer units SU adjacent to each other may overlap or be in close contact with each other. In an implementation, the spacing bars SS1 at the ends may overlap each other between the specific pair of battery cells <NUM> (e.g., two spacing bars SS1 from two different but adjacent spacer units SU may together protrude between the specific pair of battery cells <NUM>). In an implementation, in the spacer units SU adjacent to each other in the first direction Z1, the spacing bars SS1 at the ends may overlap each other, to provide a structure that is advantageous in the rigidity of the battery pack in the first direction Z1. In another case where spacer units SU adjacent to each other do not overlap each other, a binding force between the spacer units SU adjacent to each other may deteriorate, and thus, the rigidity in the first direction Z1 may also deteriorate. In an implementation, in the spacer units SU adjacent to each other, the spacing bars SS1 at the ends of the spacer units SU may overlap each other and be between the specific pair of battery cells <NUM>, and thus, binding between the spacing bars SS1 at the ends may be strengthened, and accordingly, binding between the spacer units SU (structurally separated from each other) may be also strengthened, and a structure advantageous in rigidity in the first direction Z1 may be provided. In another case where the spacer units SU adjacent to each other do not overlap each other, a lateral surface <NUM> of one battery cell <NUM>, between one group of the battery cells <NUM>, the lateral surfaces <NUM> of which are covered by one spacer unit SU and another group of the battery cells <NUM>, the lateral surfaces <NUM> of which are covered by the spacer unit SU adjacent to the one spacer unit SU, is not covered by any spacer unit SU, and the spacer units SU adjacent to each other may be separated from each other due to the one battery cell <NUM> therebetween, such that the rigidity of the battery pack in the first direction Z1 may deteriorate.

In an implementation, the specific pair of battery cells <NUM>, between which the spacing bars SS1 of the respective ends of the spacer units SU adjacent to each other overlap each other, may be related to the number n of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) that one spacer unit SU extends across. In an implementation, in the case where, as illustrated in <FIG>, the k number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) are arranged in the first direction Z1 in one module BM, e.g., first, second,. , (k-<NUM>)th, and kth battery cells are arranged in the first direction Z1 in one module BM, the specific pairs of battery cells <NUM>, each between which the spacing bars SS1 of the respective ends of the spacer units SU adjacent to each other overlap each other, may include an nth battery cell (e.g., a fourth battery cell), an (n+<NUM>)th battery cell (e.g., a fifth battery cell), a (<NUM>*n)th battery cell (e.g., an eighth battery cell), and a (<NUM>*n+<NUM>)th battery cell (e.g., a ninth battery cell), e.g., every (n*i, wherein i is an integer)th battery cell and every (n*i+<NUM>)th battery cell, in the case where one spacer unit SU extends across the n battery cells <NUM> (e.g., <NUM> battery cells <NUM>).

Referring to <FIG>, the plurality of spacing bar SS are arranged or spaced apart in the first direction Z1. In an implementation, the spacing bars SS1 at the ends of each spacer unit SU and the spacing bars SS2 at central portions (between the ends of the spacer unit SU in the first direction Z1) may have different thicknesses t1 and t2 (e.g., as measured in the first direction Z1). As described above, in the spacer units SU adjacent to each other, the spacing bars SS1 at the ends adjacent to or facing each other may be arranged to overlap each other between the specific pair of battery cells <NUM>, and the thickness t1 of the spacing bars SS1 at the ends may be half of the thickness t2 of the spacing bars SS2 at the central portions, such that the gaps between the battery cells <NUM> adjacent to each other are uniform throughout the battery cells <NUM> arranged in the first direction Z1.

Referring to <FIG> and <FIG>, in an embodiment, the plurality of spacer units SU that are structurally separated from each other may be continuously arranged in the first direction Z1 such that the spacers S extend across all of the battery cells <NUM>. In addition, the plurality of spacer units SU structurally separated from each other and continuously arranged in the first direction Z1, rather than the one spacer S structurally extending in the first direction Z1, may help reduce stress accumulated in the spacers S due to swelling of the battery cells <NUM>. In addition, by including the plurality of spacer units SU structurally separated from each other, all the spacers S may be prevented from being accumulatively deformed due to thermal deformation that could occur during molding, e.g., distortion that may occur in cooling a hot molten resin. In an implementation, in the case of the swelling where the battery cells <NUM> are swollen during charging and discharging, the battery cells <NUM> may be forcibly moved accumulatively according to their positions in the first direction Z1. In some cases, the battery cells <NUM> at both sides of the battery cells <NUM> at central portions among the m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) may be forcibly moved accumulatively according to their specific positions in the first direction Z1, and accordingly, stress accumulation may be caused between the battery cells <NUM> and the spacers S for restricting positions of the battery cells <NUM>. In an implementation, by partially allowing a position movement in the first direction Z1 through an arrangement of the plurality of spacer units SU structurally separated from each other, the stress accumulation between the battery cells <NUM> and the spacer units SU may be resolved, e.g., stress accumulation that may be cumulatively generated in a structure in which the plurality of battery cells <NUM> are arranged may be resolved.

Referring to <FIG>, the battery pack according to an embodiment may be configured to be expandable in the module BM, e.g., the battery pack may be expandable in the module BM by adding the spacer units SU structurally separated from each other, e.g., by adding another spacer unit SU to the existing module BM without having to replace the spacers S of the existing module BM. The spacer unit SU may be integrally formed of an electrically insulating resin material. In an implementation, the spacer unit SU may be between the battery cells <NUM> and the side plate <NUM> to electrically insulate the battery cells <NUM> from the side plate <NUM>.

Referring to <FIG> and <FIG>, the battery pack according to an embodiment may be configured to be expandable in the module BM, and may include a total of m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) while repeating the module BM in the first direction Z1, in which k (k<m) number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) are in one module. In an implementation, the m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) constituting the battery pack may be divided into the modules BM each including the k battery cells <NUM> (e.g., <NUM> battery cells <NUM>). In this case, the m number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) of the battery pack may be a (e.g., whole number) multiple of the k number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) constituting one module BM. In an implementation, the battery pack may include a total of <NUM> battery cells <NUM>, and two modules BM may be continuously arranged, in which <NUM> battery cells <NUM> are in each module BM. In an implementation, a second end block <NUM> may be arranged between the modules BM adjacent to each other (e.g., in the first direction Z1). In addition to the second end block <NUM> arranged between the modules BM adjacent to each other, the pair of first end blocks <NUM> may be arranged at a front side and a rear side of the battery pack, and the first and second end blocks <NUM> and <NUM> may have substantially the same structure. The detailed technical features of the first and second end blocks <NUM> and <NUM> will be described below.

The total of m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1 may be entirely covered by (e.g., laterally between) the pair of first end blocks <NUM> and a pair of the side plates <NUM>. The pair of first end blocks <NUM> and the pair of side plates <NUM> may cover outer (e.g., lateral) surfaces of all the battery cells <NUM>, to bind all the battery cells <NUM> in a single pack structure and secure the structural rigidity of the battery pack. In an implementation, the side plate <NUM> may extend (e.g., lengthwise) in the first direction Z1, and the first end block <NUM> may extend (e.g., lengthwise) in the second direction Z2. The side plate <NUM> and the first end block <NUM> may be coupled to each other by welding or the like at a corner where the side plate <NUM> and the first end block <NUM> contact each other, to cover the outer surfaces of all the battery cells <NUM> in the first direction Z1 and the second direction Z2. The pair of first end blocks <NUM> may be arranged at the front and rear of all the battery cells <NUM> (e.g., the collective row of battery cells <NUM>) in the first direction Z1, respectively, and may extend (e.g., lengthwise) in the second direction Z2 to cover the foremost (e.g., of a front one of the battery cells <NUM>) and rearmost (e.g., of a rear one of the battery cells <NUM>) large surfaces <NUM> of all the battery cells <NUM>, respectively. The pair of side plates <NUM> may be arranged to face each other in the second direction Z2 with the battery cells <NUM> therebetween, and may extend in the first direction Z1 to cover the lateral surfaces <NUM> of the battery cells <NUM>.

The first end blocks <NUM> may cover the front and rear of the total of m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1 (e.g., the front side and the rear side of the entire row of battery cells <NUM>), and may cover the foremost large surface <NUM> of the foremost or front battery cell <NUM> and rearmost large surface <NUM> of the rearmost or rear battery cell <NUM>, e.g., at both or opposite ends (of the row of battery cells <NUM>) in the first direction Z1. The pair of first end blocks <NUM> may be at both ends of all the battery cells <NUM> in the first direction Z1, may structurally bind all the battery cells <NUM> in the first direction Z1, and may insulate and protect the battery cells <NUM> from external environments. The outer surface of the battery cell <NUM> may have an electrical polarity according to a specific structure, and the battery cell <NUM> may be insulated from the external environments by covering the battery cell <NUM> with the first end blocks <NUM> having electrical insulation. In an implementation, the first end block <NUM> may be formed of an insulating resin material, and may cover or face the large surface <NUM> of the battery cell <NUM> with the resin material that is advantageous in terms of rigidity, such that curved swelling of the large surface <NUM> of the battery cell <NUM> may be effectively suppressed, and a change in electrical characteristics due to deformation of the battery cell <NUM> and a consequent deterioration in charging and discharging characteristics may be effectively prevented.

In an implementation, the first end block <NUM> may be hollow, e.g., having at least a portion thereof empty, and accordingly, the battery pack may be advantageous in reducing production costs and in reducing its weight. The first end block <NUM> may be formed entirely of a resin material, and coupling blocks 110c protruding in the second direction Z2 may be at both ends of the first end block <NUM>. The coupling blocks 110c at both ends of the first end block <NUM> may provide position alignment with coupling ends 140c at both ends of the side plate <NUM>, e.g., the first end block <NUM> and the side plate <NUM> may be coupled to each other by welding or fastening using a separate fastener, e.g., a bolt, between the first end block <NUM> and the end of the side plate <NUM> in a state in which the coupling block 110c and the coupling end 140c are aligned with respect to each other.

Bush units or coupling holes 110a may be at both ends of the first end block <NUM>. The coupling holes 110a may have a hollow shape, e.g., a hollow cylindrical shape, and a fastener inserted into the coupling holes 110a may be fastened to a mounting plate on which the battery pack is mounted, accordingly, the entire battery pack may be fixed on the mounting plate. The mounting plate may be in an apparatus in which the battery pack is mounted, and may be provided in, e.g., an electric vehicle to provide an installation place of the battery pack. In an implementation, the coupling holes 110a may be at four symmetrical positions of the battery pack, e.g., at both ends, in the second direction Z2, of the pair of the first end blocks <NUM> that cover the foremost and rearmost battery cells <NUM> in the first direction Z1, such that the battery pack may be stably fixed in the apparatus.

The pair of first end blocks <NUM> may be arranged at both ends of the total of m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1, and, in the battery pack expanded with additional modules BM, with k number of battery cells <NUM> (e.g., <NUM> battery cells <NUM>) in each module BM, the second end block <NUM> may be arranged between the modules BM adjacent to each other. The second end block <NUM> may have substantially the same structure as that of the first end block <NUM>, a detailed structure of the second end block <NUM> may be substantially the same as that of the first end block <NUM>, and a repeated description thereof may be omitted. In an implementation, coupling blocks 120c at both ends of the second end block <NUM> may be aligned with the coupling ends 140c of the side plates <NUM>, and the entire battery pack may be firmly fixed through the fasteners fastened to the mounting plate by passing through the coupling holes 120a at both ends of the second end blocks <NUM>.

As will be described below, when expanding the battery pack with additional modules BM, the first end block <NUM> of the existing module BM may then function as the second end block <NUM> when adding of the additional modules BM, and thus, the first and second end blocks <NUM> and <NUM> may have substantially the same structure.

The battery pack according to an embodiment may be configured to be expandable in the module BM. In an implementation, upon addition of a new module BM, any one of the first end blocks <NUM> arranged at both ends of the existing module BM may then be the second end block <NUM> from or at which the new module BM is added, such that the second end block <NUM> is between the first end block <NUM> arranged at the end of the new module BM and the first end block <NUM> of the existing module BM.

The coupling blocks 120c may be at both ends of the second end block <NUM> between the existing module BM and the new module BM, and after the coupling blocks 120c of the second end block <NUM> are aligned with the coupling ends 140c of the side plates <NUM>, the second end block <NUM> and the side plates <NUM> may be coupled to each other to secure the rigidity in the first direction Z1, and by securing rigidity between the modules BM adjacent to each other, the warpage or distortion of the battery pack in the first direction Z1 may be reduced or prevented.

The coupling holes 120a may be at both ends of the second end block <NUM> between the existing module BM and the new module BM, and the fastener passing through the coupling holes 120a of the second end block <NUM> may be fastened to the mounting plate, and thus, a fastening position of the battery pack may be additionally provided between the pair of first end blocks <NUM> in addition to the pair of first end blocks <NUM> at both ends of the battery pack, and accordingly, the battery pack that extends in the module BM may be stably fixed on the mounting plate.

The side plates <NUM> may extend in the first direction Z1, may extend across the lateral surfaces <NUM> of the total of m battery cells <NUM> (e.g., <NUM> battery cells <NUM>) arranged in the first direction Z1, and may cover the lateral surfaces <NUM> of the battery cells <NUM>. The side plates <NUM> may extend in the first direction Z1 to contribute to the rigidity of the battery pack in the first direction Z1, and may facilitate the rigidity to resist the warpage or distortion in the first direction Z1. Reinforcing ribs 140b (having a concave or convex shape) may be in or on the side plate <NUM>. In an implementation, the reinforcing rib 140b may extend in the first direction Z1 over or along an entire length of the side plate <NUM> and may be concave to face the battery cells <NUM> from an inner surface of the side plate <NUM>. In an implementation, the reinforcing rib 140b may be concave from the inner surface of the side plate <NUM> to face the battery cells <NUM>, and an outer surface of the side plate <NUM> may be flat, such that interference with a space inside the apparatus in which the battery pack is mounted may be avoided. In this case, the reinforcing ribs 140b of the side plate <NUM> may also accommodate the protruding surfaces SP (see <FIG>) of the spacer S and may be formed to be concave to accommodate the protruding surfaces SP of the spacer S.

The side plates <NUM> may extend across the lateral surfaces <NUM> of the battery cells <NUM> in the first direction Z1 to contribute to heat dissipation of the battery cells <NUM>, and to this end, the side plates <NUM> may be formed of a metal material having excellent heat dissipation characteristics, e.g., aluminum or an aluminum alloy. In addition, the side plate <NUM> made of the metal material may provide a structure with excellent impact resistance characteristics.

The pair of coupling ends 140c forming the ends of the side plate <NUM> may be at both (e.g., opposite) ends of the side plate <NUM> in the first direction Z1, and the first end block <NUM> and the side plate <NUM> may be coupled to each other by welding or fastening using the separate fastener, e.g., a bolt, between the first end block <NUM> and the end of the side plate <NUM> in a state in which the coupling block 110c and the coupling end 140c are aligned with respect to each other. As described above, the outer surfaces of the battery cells <NUM> may be covered by the side plates <NUM> and the first end blocks <NUM> coupled to each other.

The side plate <NUM> may face the lateral surfaces <NUM> of the battery cells <NUM> with the spacer S therebetween, and may fix a position of the spacer S such that the spacer S is not separated from between the battery cells <NUM> adjacent to each other, e.g., by holding or pressing the spacer S toward the battery cells <NUM>. The spacers S may be formed of an insulating resin to electrically insulate the battery cells <NUM> from the side plates <NUM>.

The battery pack according to an embodiment may be expandable in the module BM, and the side plate <NUM> may be added in the module BM. In an implementation, the side plates <NUM> may be implemented in two or more side plates <NUM> divided in the module BM. In an implementation, the battery pack may be expanded in the module BM in such a manner that a new side plate <NUM> may be additionally coupled to the side plate <NUM> of the existing module BM to extend an entire length of the side plates <NUM>. In an implementation, the coupling end 140c at the end of the side plate <NUM> of the existing module BM and the coupling end 140c at the end of the new side plate <NUM> of the new module BM may be aligned with respect to the coupling block 120c of the second end block <NUM> between the existing module BM and the new module BM, and the side plate <NUM> of the existing module BM and the new side plate <NUM> of the new module BM may be coupled to each other on the second end block <NUM> by welding or coupling, to enable the battery back to be expanded in the module BM. In an implementation, the new module BM may be added from or at the second end block <NUM> such that any one of the pair of first end blocks <NUM> at ends of the existing module BM may function as the second end block <NUM> (of the expanded battery module BM), and in this case, the side plate <NUM> of the existing module BM may be already welded to the second end block <NUM>. By further welding the new side plate <NUM> of the new module BM to the second end block <NUM> to which the side plate <NUM> of the existing module BM has been welded, a structure in which the side plate <NUM> of the existing module BM and the new side plate <NUM> are welded to the second end block <NUM> between the existing module BM and the new module BM may be implemented, and as a result, the side plates <NUM> may be expanded in the module BM.

The side plate <NUM> may include a protruding piece 140a supporting the terminal surfaces <NUM> of the battery cells <NUM>. The protruding piece 140a may protrude from a body of the side plate <NUM> (covering the lateral surfaces <NUM> of the battery cells <NUM>) toward (e.g., over) the battery cells <NUM> and may support (e.g., face) the terminal surfaces <NUM> of the battery cells <NUM>. In an implementation, the protruding piece 140a may support the terminal surfaces <NUM> of the battery cells <NUM> by interposing an edge of a bus bar holder BH extending across the terminal surfaces <NUM> of the battery cells <NUM>. In an implementation, the bus bar holder BH may be between the protruding piece 140a and the terminal surfaces <NUM> of the battery cells <NUM>. The detailed technical features of the bus bar holder BH will be described below.

In an implementation, an additional protruding piece may be formed on the side plate <NUM> to support the bottom surfaces <NUM> of the battery cells <NUM>. In an implementation, the additional protruding piece may protrude from the body of the side plate <NUM> (covering the lateral surfaces <NUM> of the battery cells <NUM>) toward (e.g., under) the battery cells <NUM> to support the bottom surfaces <NUM> of the battery cells <NUM> or directly support the bottom surfaces <NUM> of the battery cells <NUM>. In an implementation, the bottom surfaces <NUM> of the battery cells <NUM> may be supported by the bottom connection bar SC2 (see <FIG>) of the spacer S, and the additional protruding piece of the side plate <NUM> may be omitted. In an implementation, the bottom connection bar SC2 of the spacer S and the additional protruding portion of the side plate <NUM> may overlap each other on the bottom surfaces <NUM> of the battery cells <NUM>, thereby causing interference.

In an implementation, the battery cells <NUM> may be more firmly fixed with the protruding pieces 140a of the side plates <NUM> supporting the terminal surfaces <NUM> of the battery cells <NUM> and the bottom connection bars SC2 (see <FIG>) of the spacers S supporting the bottom surfaces <NUM> of the battery cells <NUM>. In an implementation, the protruding piece 140a may be bent from the body of the side plate <NUM> toward the battery cells <NUM> to reinforce rigidity of the side plate <NUM> and the rigidity of the entire battery pack in the first direction Z1.

Referring to <FIG>, the bus bar holder BH may be arranged on the terminal surfaces <NUM> of the battery cells <NUM>. The bus bar holder BH may guide assembly positions of bus bars B electrically connected to the first and second electrode terminals 11a and 11b on the terminal surfaces <NUM> of the battery cells <NUM>, and may maintain the assembly positions of the bus bars B at normal positions. In addition, the bus bar holder BH may block electrical interference between the battery cells <NUM> and the bus bars B and may block electrical interference between a circuit unit arranged on the bus bar holder BH and the battery cells <NUM>.

In an implementation, the bus bar holder BH may extend across the terminal surfaces <NUM> of the plurality of battery cells <NUM> to guide the assembly positions of a plurality of bus bars B electrically connected to the plurality of battery cells <NUM>. A plurality of terminal holes exposing the first and second electrode terminals 11a and 11b of the battery cells <NUM>, respectively, may be arranged on the bus bar holder BH, and the bus bars B may be coupled to the first and second electrode terminals 11a and 11b exposed from the bus bar holder BH through the terminal holes, to electrically connect the battery cells <NUM> to each other. In an implementation, the first and second electrode terminals 11a and 11b exposed through the terminal holes of the bus bar holder BH may be coupled to the bus bars B by welding.

In an implementation, after the spacers S are assembled onto the lateral surfaces <NUM> of the battery cells <NUM>, the bus bar holder BH may be assembled onto the terminal surfaces <NUM> of the battery cells <NUM>, and then the side plates <NUM> may be sequentially assembled onto the spacers S assembled onto the lateral surfaces <NUM> of the battery cells <NUM>. In an implementation, the spacers S may be assembled to face each other at opposite lateral surfaces <NUM> of the battery cells <NUM> therebetween, such that the lateral connection bars SC1 and the bottom connection bars SC2 of the spacers S extend across the lateral surfaces <NUM> and the bottom surfaces <NUM> of the battery cell <NUM>, respectively. After the bus bar holder BH is arranged on the terminal surfaces <NUM> of the battery cells <NUM>, the side plates <NUM> may be assembled to face each other at both lateral surfaces <NUM> of the battery cells <NUM> therebetween, such that the protruding pieces 140a formed on the side plates <NUM> are put on the edges of the bus bar holder BH arranged on the terminal surfaces <NUM> of the battery cells <NUM>.

<FIG> is a diagram of coupling between the first and second end blocks and the side plates according to an embodiment modified from that of <FIG>.

Referring to <FIG>, coupling holes <NUM> may be at both ends of the side plate <NUM> in the first direction Z1, and the first end blocks <NUM> and the side plates <NUM> may be coupled to each other by fastening using bolts <NUM> in a state in which the coupling holes <NUM> of the side plates <NUM> are aligned with the coupling holes <NUM> at both ends of the first end blocks <NUM>. As described above, the outer surfaces of all the battery cells <NUM> may be covered by the side plates <NUM> and the first end blocks <NUM> coupled to each other. In addition, the coupling holes <NUM> at both ends of the second end block <NUM> may be aligned with the coupling holes <NUM> of the side plates <NUM>, and the entire battery pack may be firmly fixed by the fasteners fastened to the mounting plate through the coupling holes 120a at both ends of the second end block <NUM>.

By way of summation and review, small mobile devices such as mobile phones may operate for a predetermined time by using an output and a capacity of a single battery. In the case of electric automobiles or hybrid automobiles, which may have large power consumption, a long driving time, and high-power driving, battery packs may be used to meet the power and capacity requirements, and an output voltage or an output current of a battery pack may increase as the number of battery cells embedded therein increases.

In one or more embodiments the spacer structure may be capable of reinforcing structural rigidity in an arrangement direction of battery cells while providing a gap capable of accommodating swelling between the battery cells adjacent to each other is applied.

One or more embodiments may provide a battery pack configured to be expandable in a module unit.

Claim 1:
A battery pack, comprising:
- a number, m, of battery cells (<NUM>) arranged in a first direction (Z1), wherein each of the battery cells (<NUM>) includes:
a terminal surface including at least one electrode terminal thereon,
a bottom surface opposite to the terminal surface in a third direction (Z3) that perpendicularly intersects with the first direction (Z1),
a pair of large surfaces at opposite sides of the battery cells (<NUM>) in the first direction (Z1) that connect the terminal surface to the bottom surface, each large surface having a first area, and
a pair of lateral surfaces at opposite sides of the battery cells (<NUM>) in a second direction (Z2) that perpendicularly intersects with the first direction (Z1) and the third direction (Z3) and that connect the terminal surface to the bottom surface, each lateral surface having a second area, the second area being smaller than the first area,
- a plurality of spacer units (SU), wherein each of the spacer units (SU) extends across a number, n, of the battery cells, in which n < m, each spacer unit (SU) including << - >> in the first direction (Z1) and connecting the plurality of spacing bars (SS) to each other;
<< a plurality of spacing bars (SS) extending in the third direction (Z3) and disposed between the large surfaces of adjacent battery cells (<NUM>); and connection bars (SC) extending >>
wherein a plurality of spacer units (SU) arranged in the first direction (Z1) form a spacer (S), and wherein spacers (S) facing each other in the second direction (Z2) form a pair of spacers, the spacers (S) of a pair of spacers being fixed to the lateral surfaces on opposite sides of the battery cells (<NUM>), such that the spacing bars (SS) belonging to a pair of spacers (S) form pairs of spacing bars facing each other in the second direction (Z2).