Patent Description:
In general, a battery cell may be repeatedly charged and discharged by an electrochemical reaction of components thereof. A battery pack may include a plurality of battery cells to increase an output voltage or an output current.

Here, since the battery cells of the battery pack are densely arranged, it is important to dissipate heat generated from each of the battery cells. When the heat generated from the battery cells are not properly dissipated in a charge and discharge process, heat accumulation may be generated in the battery pack to overheat the battery cells. Thus, the battery cells may be ignited and exploded.

Typically, when the battery pack is manufactured, a filling material is injected to a space between the battery cells. Since the filling material may fix the battery cells and easily dissipate the heat generated from the battery cells, the filling material may retard or prevent the ignition or explosion of the battery cells. However, the filling material is difficult to be uniformly filled in the entire space between the battery cells, and the filling of the filling material into the space between the battery cells requires much time and costs.

(Patent document <NUM>) <CIT>
<CIT> discloses a battery module including a plurality of cylindrical battery cells electrically connected to each other and arranged in a horizontal direction, an upper frame mounted on the plurality of cylindrical battery cells, and a lower frame mounted below the plurality of cylindrical battery cells, wherein a pressing portion is formed in any one of the upper frame and the lower frame to elastically press the plurality of cylindrical battery cells in a horizontal inward direction for a dense arrangement of the plurality of cylindrical battery cells. <CIT> relates to a battery module comprising: a plurality of cylindrical battery cells; and a first fixing frame for supporting the cylindrical battery cells such that the cylindrical battery cells are arranged to stand up, wherein the first fixing frame includes: cell lower-end holder parts having a tray shape, and provided such that the cylindrical battery cells are erected and inserted, one by one, at each of predetermined positions on a plate; through-holes penetratively formed in a vertical direction among the cell lower-end holder parts; and a thermally conductive adhesive liquid flowing from the lower part to the upper part of the first fixing frame through the through-holes.

The present disclosure provides a battery pack capable of stably supporting and storing battery cells and a manufacturing method thereof.

The present disclosure also provides a battery pack capable of decreasing a usage amount of a filling material filled in a space between battery cells and a manufacturing method thereof.

In accordance with an aspect of the present invention, a battery pack(<NUM>) includes: a frame (<NUM>) having an inner space and an opened one side; a plurality of battery cells (<NUM>) each having one end disposed in the inner space of the frame (<NUM>) and the other end protruding to the outside of one side of the frame (<NUM>); a cell holder (<NUM>) having a plurality of insertion holes to which the other ends of the battery cells (<NUM>) are respectively inserted and installed at one side of the frame (<NUM>); a heat sink (<NUM>) installed on the cell holder (<NUM>) to cool the battery cells (<NUM>); a plurality of supports (<NUM>) disposed in a portion of a space between the battery cells (<NUM>); and a filling material (<NUM>) filled in the rest space in which the supports (<NUM>) are not disposed in the space between the battery cells (<NUM>), wherein the cell holder (<NUM>) is provided in plurality, and a plurality of cell holders are stacked in a vertical direction. Here, a filled amount of the filling material is adjusted according to the number of the provided supports.

The support (<NUM>) may be formed along a flat surface shape of the space between the battery cells (<NUM>) and extend less than a height of the inner space of the frame (<NUM>).

Groups formed as the battery cells (<NUM>) are arranged along one direction may be arranged so that the battery cells (<NUM>) are arranged in a row along a direction perpendicularly crossing the one direction, and each of the groups may include the same number of battery cells (<NUM>).

Groups formed as the battery cells (<NUM>) are arranged along one direction may be arranged so that the battery cells (<NUM>) are alternately arranged in a direction perpendicularly crossing the one direction, and the support (<NUM>) may have a triangular shape in which a perimeter of a flat surface of the support (<NUM>) has three sides.

Each of the sides of the perimeter of the flat surface of the support (<NUM>) may have one of a curved shape or a straight line shape.

The cell holder is provided in plurality, and a plurality of cell holders are stacked in a vertical direction.

In accordance with the present invention, a method for manufacturing a battery pack (<NUM>) includes: storing one ends of battery cells (<NUM>) in an inner space of a frame (<NUM>); installing a plurality of supports (<NUM>) in a portion of a space between the battery cells (<NUM>); installing a cell holder (<NUM>) at one side of the frame (<NUM>) and respectively inserting the other ends of the battery cells (<NUM>) protruding to the outside of the frame (<NUM>) to insertion holes formed in the cell holder (<NUM>); and injecting a filling material (<NUM>) into the rest space in which the supports (<NUM>) are not installed in the space between the battery cells (<NUM>). Here, the installing of the plurality of supports (<NUM>) includes setting the number of provided supports (<NUM>) to adjust a filled amount of the filling material (<NUM>).

The setting of the number of provided supports (<NUM>) includes installing the supports (<NUM>) to occupy <NUM>% or more to <NUM>% or less of a volume of an entire space between the battery cells (<NUM>).

The installing of the cell holder (<NUM>) at one side of the frame (<NUM>) may include stacking a plurality of cell holders (<NUM>) in a vertical direction and coupling the cell holders (<NUM>) to the frame.

A material of the filling material (<NUM>) may include silicon.

Exemplary embodiments can be understood in more detail from the following description taken in conjunction with the accompanying drawings, in which:.

Hereinafter, specific embodiments will be described in detail with reference to the accompanying drawings. The present disclosure may, however, be embodied in many different forms and should not be construed as being 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 concept of the invention to those skilled in the art. In the figures, the dimensions of layers and regions are exaggerated for clarity of illustration, and like reference numerals refer to like elements throughout.

<FIG> is a perspective view illustrating a battery pack in accordance with an exemplary embodiment, <FIG> is an exploded perspective view illustrating a structure of the battery pack in accordance with an exemplary embodiment, and <FIG> is a plan view illustrating an installation structure of supports in accordance with an exemplary embodiment. Hereinafter, the battery pack in accordance with an exemplary embodiment will be described.

The battery pack in accordance with an exemplary embodiment is a device for supplying power to electronic equipment or system. Referring to <FIG> and <FIG>, a battery pack <NUM> includes a frame <NUM>, a battery cell <NUM>, a cell holder <NUM>, a heat sink <NUM>, a filling material <NUM>, and a support <NUM>.

The battery cell <NUM> may have a cylindrical shape. For example, the battery cell <NUM> may be a secondary battery cell and include a positive electrode collector, a negative electrode collector, a separator, an active material, and an electrolyte. The battery cell <NUM> may be repeatedly charged and discharged by an electrochemical reaction of the above-described components thereof.

Here, the battery cell <NUM> is provided in plurality. The battery cells <NUM> may be spaced apart from each other at predetermined positions. The battery cells <NUM> may be electrically connected in series or parallel. Thus, the battery pack <NUM> may increase an output voltage or an output current.

Also, each of the battery cells <NUM> may have one end (or upper end) disposed in an inner space of the frame <NUM> and the other end (or lower end) protruding to the outside of one side (or lower side) of the frame <NUM>. That is, the battery cells <NUM> may have a length extending in one direction (or vertical direction) greater than that of the frame <NUM>.

The frame <NUM> may have a chamber shape. For example, the frame <NUM> may have a cuboid box shape. Thus, the frame <NUM> may have an inner space for accommodating the battery cells <NUM>.

Here, the frame <NUM> may have an opened one side (or lower side). For example, as the entire low side of the frame <NUM> is opened, an opening may be formed. Thus, the battery cells <NUM> may be entered to the inside of the frame <NUM> through the opening. Since each of the battery cells <NUM> has the length in the vertical direction greater than that of the frame <NUM>, the lower end of each of the battery cells <NUM> may pass through the opening and protrude from the lower side of the frame <NUM>.

Also, a plurality of through-holes A may be defined in the other side (or top surface) of the frame <NUM>. For example, the through-holes A may each have a circular shape and be arranged in the form of a x b. A terminal disposed at the upper end of the battery cell <NUM> may be inserted to the through-hole A. Thus, as the terminals of the battery cells <NUM> are inserted to the different through-holes A, respectively, the battery cells <NUM> may be arranged in the form of a x b based on an array of the through-holes A.

Here, the terminals of the battery cells <NUM> may be respectively inserted to the through-holes A and exposed to the outside of the frame <NUM>. A busbar <NUM> may be installed on the frame <NUM> and connected with the terminals. For example, the busbar <NUM> may extend in one direction (or front and rear direction) and be provided in plurality, so that a plurality of busbars <NUM> are spaced apart from each other in the other direction (or left and right direction). Thus, the battery cells <NUM> spaced apart from each other in one direction may be electrically connected to each other by the busbars <NUM>. However, the exemplary embodiment is not limited to the number of the busbars <NUM> and the structure of electrically connecting the battery cells <NUM>. For example, the number of the busbars <NUM> and the structure of electrically connecting the battery cells <NUM> may be variously provided.

Also, the frame <NUM> may have an opened one surface (or front surface). Thus, the filling material <NUM> may be injected to the inner space of the frame <NUM> through the opened front surface. However, the exemplary embodiment is not limited to the structure and shape of the frame <NUM>. For example, the frame <NUM> may have various structures and shapes.

The cell holder <NUM> may have a plate shape. For example, the cell holder <NUM> may have a rectangular shape along a flat surface shape of the frame <NUM>, and an area of a top surface of the cell holder <NUM> may be equal to or greater than that of the flat surface of the frame <NUM>. Thus, when the cell holder <NUM> is installed so that a perimeter of the top surface of the cell holder <NUM> contacts an one side end of the frame <NUM>, the cell holder <NUM> may cover an entire cross-section (or lower portion) of the inner space of the frame <NUM>. Thus, a lower opening formed in the frame <NUM> may be sealed by the cell holder <NUM>.

Here, a material of the cell holder <NUM> may include plastic. Thus, the cell holder <NUM> may be manufactured at less cost than the filling material <NUM> made of silicon.

Also, a plurality of insertion holes B may be defined in the cell holder <NUM>. Each of the insertion holes B may be formed along a circumferential shape of the battery cell <NUM>, and an internal diameter of the insertion hole B may be equal to or greater than an external diameter of the battery cell <NUM>. Thus, the other ends of the battery cells <NUM> may pass through and be inserted to the insertion holes B, respectively.

Here, the insertion holes B may respectively face the through-holes A of the frame <NUM>. That is the insertion holes B may be arranged in the form of a x b based on the array of the through-holes A. Thus, the battery cell <NUM> may have the upper end inserted to and supported by the through-hole A and the lower end inserted to and supported by the insertion hole B. Thus, the battery cells <NUM> may maintain a stably fixed state.

The cell holder <NUM> is provided in plurality. The cell holders <NUM> may be stacked to each other between the frame <NUM> and the heat sink <NUM>. For example, as a first cell holder 150a and a second cell holder 150b are provided, the cell holders <NUM> may be stacked in a vertical direction and disposed in a spaced space between the frame <NUM> and the heat sink <NUM>. Thus, a top surface of the first cell holder 150a may be connected to the lower portion of the frame <NUM>, and a bottom surface of the second cell holder 150b may be connected to the heat sink <NUM>. However, the exemplary embodiment is not limited to the number of the cell holders <NUM>. For example, three or more cell holders may be provided instead of two cell holders.

Here, the cell holders <NUM> may support the battery cells <NUM> together with the filling material <NUM>. That is, the filling material <NUM> supports a perimeter of the one end (or upper end) of each of the battery cells <NUM>, and each of the cell holders <NUM> supports a perimeter of the other end (or lower end) of each of the battery cells <NUM> except for the upper end of each of the battery cells <NUM>. Since the filling material <NUM> is not filled in a space in which the cell holders <NUM> are disposed, as a portion supported by the cell holders <NUM> is increased in the battery cell <NUM>, a portion supported by the filling material <NUM> may be decreased. Thus, a volume of the inner space of the frame <NUM> and an amount of the filling material <NUM> filled in the inner space of the frame <NUM> may be adjusted according to the number of staked cell holders <NUM>.

For example, when the number of the provided cell holders <NUM> is increased, the volume of the inner space of the frame <NUM> may be decreased, and when the number of the provided cell holders <NUM> is decreased, the volume of the inner space of the frame <NUM> may be increased. Thus, when the volume of the inner space of the frame <NUM> is decreased, the amount of the filling material <NUM> filled in the inner space of the frame <NUM> may be decreased, and when the volume of the inner space of the frame <NUM> is increased, the amount of the filling material <NUM> filled in the inner space of the frame <NUM> may be increased. Thus, the usage amount of the filling material <NUM> may be decreased by adjusting the stacked number or height of the cell holders <NUM>.

The heat sink <NUM> may be disposed below the cell holder <NUM>. Thus, the heat sink <NUM> may directly or indirectly contact the battery cells <NUM> inserted to the cell holder <NUM> to cool the battery cells <NUM>. The heat sink <NUM> may include a cooling member <NUM>, a cooling medium supply member <NUM>, and a cooling medium discharge member <NUM>.

The cooling member <NUM> may have a plate shape. For example, the cooling member <NUM> may have a rectangular shape along a flat surface shape of the cell holder <NUM>, and an area of a top surface of the cooling member <NUM> may be equal to or greater than that of a flat surface of the cell holder <NUM>. Thus, the top surface of the cooling member <NUM> may directly or indirectly contact all of the battery cells <NUM>.

Also, a flow path through which the cooling medium moves may be formed in the cooling member <NUM>. For example, the cooling medium may be a coolant. Thus, the cooling medium moving along the flow path formed in the cooling member <NUM> may absorb heat generated from the battery cells <NUM>. Thus, the battery cells <NUM> may be cooled as a temperature thereof is decreased by the cooling medium.

Here, the cooling member <NUM> may be made of a material having a high thermal conductivity. For example, the cooling member <NUM> may be made of aluminum or an aluminum alloy material. Thus, the cooling member <NUM> may easily transfer the heat generated from the battery cells <NUM> to the cooling medium. Thus, the temperature of the battery cells <NUM> may be quickly adjusted.

The cooling medium supply member <NUM> may be connected to the cooling member <NUM>. For example, the cooling medium supply member <NUM> may be a line for supplying the cooling medium to the cooling member <NUM> and connected to one end of the flow path formed in the cooling member <NUM>. Thus, the cooling medium supplied to the one end of the flow path through the cooling medium supply member <NUM> may absorb the heat of the battery cells <NUM> while passing through the flow path.

The cooling medium discharge member <NUM> may be connected to the cooling member <NUM>. For example, the cooling medium supply member <NUM> may be a line for discharging the cooling medium in the cooling member <NUM> and connected to the other end of the flow path formed in the cooling member <NUM>. Thus, the cooling medium may move from the one end to the other end of the flow path and be discharged to the outside through the cooling medium discharge member <NUM>. However, the exemplary embodiment is not limited to the structure and shape of the housing <NUM>. For example, the housing may have various structures and shapes.

The filling material <NUM> may be supplied to the inner space of the frame <NUM> and filled in the space between the battery cells <NUM>. Since the support <NUM> is installed in the space between the battery cells <NUM> in advance, the filling material <NUM> may be filled in the rest space in which the supports <NUM> are not disposed in the space between the battery cells <NUM>. Thus, the filling material <NUM> may hold the upper portions of the battery cells <NUM> together with the supports <NUM>.

Also, a material of the filling material <NUM> may include silicon. Thus, the filling material <NUM> may simultaneously have a thermal conductivity and an adhesive property. Thus, the filling material <NUM> may be easily formed along a shape of the space between the battery cells <NUM> to fix the battery cells <NUM> and transfer the heat generated from the battery cells <NUM> to the outside.

Here, a feature of providing the filling material <NUM> to the entire space between the battery cells <NUM> may require much time and costs. Thus, the usage amount of the filling material <NUM> may be decreased by including the cell holders <NUM> and the supports <NUM>.

The support <NUM> may be provided in plurality and disposed in a portion of the space between the battery cells <NUM>. Since the filling material <NUM> is also filled in the space between the battery cells <NUM>, a volume of the space in which the filling material <NUM> is filled may be adjusted according to the number of the provided supports <NUM>, and the amount of the filling material <NUM> to be injected may be adjusted. That is, when the number of the provided supports <NUM> is increased, an empty space between the battery cells <NUM> may be decreased, and the volume of the space filled by the filling material <NUM> may be decreased. When the number of the provided supports <NUM> is decreased, the empty space between the battery cells <NUM> may be increased, and the volume of the space filled by the filling material <NUM> may be increased.

For example, as illustrated in <FIG> and <FIG>, four supports <NUM> may be arranged in a row along the left and right direction and disposed between the battery cells <NUM> of a first column and a second column. Thus, as a space between the battery cells <NUM> of the first column and the second column is filled by the supports <NUM>, the filling material <NUM> is filled only between the battery cells <NUM> of the rest columns except for the space between the battery cells <NUM> of the first column and the second column. Thus, the usage amount of the filling material <NUM> may be decreased. However, the exemplary embodiment is not limited to the number or arrangement structure of the provided supports <NUM>. For example, the supports <NUM> may have various structures and provided numbers.

Also, each of the supports <NUM> may have a bar shape extending in the vertical direction. The support <NUM> may extend less than a height of the inner space of the frame <NUM>. For example, the support <NUM> may be installed on a ceiling surface of the frame <NUM> and extend downward therefrom or extend upward from the top surface of the cell holder <NUM>. Alternatively, the support <NUM> may have an upper end connected to the ceiling surface of the frame <NUM> and a lower end connected to the top surface of the cell holder <NUM>. Thus, the support <NUM> may be disposed in the inner space of the frame <NUM>.

Here, a flat surface of the support <NUM> may be formed along a flat surface shape of the space between the battery cells <NUM>. Here, a flat surface area of the support <NUM> may be equal to or less than that of the space between the battery cells <NUM>. When the flat surface area of the support <NUM> may be equal to that of the space between the battery cells <NUM>, the support <NUM> may directly contact the battery cells <NUM>, and when the flat surface area of the support <NUM> may be less than that of the space between the battery cells <NUM>, the support <NUM> may indirectly contact the battery cells <NUM>. Thus, the support <NUM> may be stably disposed in the empty space between the battery cells <NUM>.

For example, as illustrated in (a) of <FIG>, the battery cells <NUM> may be arranged along one direction (or front and rear direction) to form one group. This group may be provided in plurality, and a plurality of groups may be arranged so that the battery cells <NUM> are arranged in a row in a direction perpendicularly crossing the one direction (or left and right direction). Each of the groups may include the same number of battery cells <NUM>. Here, the support <NUM> may have a rectangular shape in which a perimeter of a flat surface has four sides. Since the battery cells <NUM> are arranged on the same line along the front and rear direction and the left and right direction, spaces surrounding by four battery cells <NUM> arranged in a rectangular shape may be formed, and the support <NUM> may be disposed at each of the spaces surrounding by different battery cells <NUM>. Thus, the four sides of the support <NUM> may face the different battery cells <NUM>. Accordingly, the sides of the support <NUM> may respectively directly or indirectly contact the facing different battery cells <NUM>, and one support <NUM> may support four battery cells <NUM>.

Alternatively, as illustrated in (b) of <FIG>, the battery cells <NUM> may be arranged along one direction (or front and rear direction) to form one group. This group may be provided in plurality, and a plurality of groups may be arranged so that the battery cells <NUM> are alternately arranged in the direction perpendicularly crossing the one direction (or left and right direction). Here, the support <NUM> may have a triangular shape in which a perimeter of a flat surface has three sides. Since the battery cells <NUM> are arranged on the same line along the front and rear direction and alternately arranged in the left and right direction, spaces surrounding by three battery cells <NUM> arranged in a triangular shape may be formed, and the support <NUM> may be disposed at each of the spaces surrounding by different battery cells <NUM>. Thus, the three sides of the support <NUM> may face the different battery cells <NUM>. Thus, the sides of the support <NUM> may respectively directly or indirectly contact the facing different battery cells <NUM>, and one support <NUM> may support three battery cells <NUM>.

Here, each of the sides of the support <NUM>, which form a perimeter of a flat surface of the support <NUM>, may have at least one of a curved shape or a straight line shape. When each of the sides of the support <NUM> has the straight line shape, the support <NUM> may be easily manufactured. When each of the sides of the support <NUM> has the curved shape, the sides of the support <NUM> may form a perimeter of the support <NUM> so that the sides respectively surround a portion of the facing battery cells <NUM>. Thus, the support <NUM> may more stably support the battery cells <NUM>.

As described above, the battery cells <NUM> may be supported by installing the plurality of supports <NUM> in a portion of the space between the battery cells <NUM>. Thus, although the amount of the filling material <NUM> used to fix the battery cells <NUM> is decreased, the battery cells <NUM> may be stably supported. Thus, an efficiency of a process of manufacturing the battery pack <NUM> may be improved by decreasing the usage amount of the filling material <NUM>.

<FIG> is a flowchart representing a method for manufacturing a battery pack in accordance with an exemplary embodiment. Hereinafter, the method for manufacturing the battery pack in accordance with an exemplary embodiment will be described.

The method for manufacturing the battery pack in accordance with an exemplary embodiment relates to a method for stably fixing the battery pack and reducing a usage amount of a filling material. Referring to <FIG>, the method for manufacturing the battery pack includes: a process S110 of storing one ends of battery cells in an inner space of a frame; a process S120 of installing a plurality of supports in a portion of a space between the battery cells; a process S130 of installing a cell holder at one side of the frame and inserting the other ends of the battery cells protruding to the outside of the frame to insertion holes formed in the cell holder; and a process S140 of injecting a filling material into the rest space in which the supports are not installed in the space between the battery cells.

Referring to <FIG>, one end (upper end) of each of battery cells <NUM> may be stored in an inner space of a frame <NUM> in the process S110. That is, the battery cells <NUM> may be entered to the inner space of the frame <NUM> through an opened one side (or lower side) of the frame <NUM>, and terminals of the battery cells <NUM> may be respectively inserted to through-holes A defined in the other side (or top surface) of the frame <NUM>. Thus, the battery cells <NUM> may be aligned along an arrangement shape of the through-holes A.

Here, each of the battery cells <NUM> may have a vertical length greater than that of the frame <NUM>. Thus, the battery cells <NUM> may have the one ends disposed in the inner space of the frame <NUM> and the other ends (or lower ends) protruding downward and disposed at the outside of the frame <NUM>.

A plurality of supports <NUM> may be installed in a portion of the space between the battery cells in the process S120. The support <NUM> may be installed on a ceiling surface of the frame <NUM> and extend downward therefrom or extend upward from a top surface of the cell holder <NUM>. Alternatively, the support <NUM> may have an upper end connected to the ceiling surface of the frame <NUM> and a lower end connected to the top surface of the cell holder <NUM>. Thus, the support <NUM> may be disposed in the inner space of the frame <NUM>.

Since the filling material <NUM> is also filled in the space between the battery cells <NUM>, a volume of the space in which the filling material <NUM> is filled may be adjusted according to the number of the provided supports <NUM>, and the amount of the filling material <NUM> to be filled may be adjusted. That is, when the number of the provided supports <NUM> is increased, an empty space between the battery cells <NUM> may be decreased, and the volume of the space filled by the filling material <NUM> may be decreased. When the number of the provided supports <NUM> is decreased, the empty space between the battery cells <NUM> may be increased, and the volume of the space filled by the filling material <NUM> may be increased.

For example, four supports <NUM> may be arranged in a row along the left and right direction and disposed between the battery cells <NUM> of a first column and a second column. Thus, as a space between the battery cells <NUM> of the first column and the second column is filled by the supports <NUM>, the filling material <NUM> is filled only between the battery cells <NUM> of the rest columns except for the space between the battery cells <NUM> of the first column and the second column. Thus, the usage amount of the filling material <NUM> may be decreased.

Here, when the number of the provided supports <NUM> is set, the supports <NUM> may be provided to occupy <NUM>% or more to <NUM>% or less of a volume of the entire space between the battery cells <NUM>. When the supports <NUM> occupy less than <NUM>% of the volume of the entire space between the battery cells <NUM>, the filled amount of the filling material may be slightly decreased, and a feature of filling the filling material <NUM> may require much time and costs like the related art. When the supports <NUM> occupy greater than <NUM>% of the volume of the entire space between the battery cells <NUM>, the usage amount of the filling material <NUM> may be extremely decreased, and the filling material <NUM> may not stably support the battery cells <NUM>. Thus, the number of the supports <NUM> may be determined to occupy <NUM>% or more to <NUM>% or less of the volume of the entire space between the battery cells <NUM> so that the filling material <NUM> stably supports the battery cells <NUM> while the usage amount of the filling material <NUM> is decreased.

Thereafter, a plurality of cell holders <NUM> may be installed at one side of the frame <NUM> in the process S130. Thus, the other ends (or lower ends) of the battery cells <NUM> protruding to the outside of the frame <NUM> may be respectively inserted to insertion holes B formed in the cell holder <NUM>. Thus, the battery cells <NUM> may be stably fixed in position as the one ends of the battery cells <NUM> are disposed in the frame <NUM>, and the other ends are supported by the cell holder <NUM>.

Also, the cell holder <NUM> may be provided in plurality. Thus, when the cell holders <NUM> are installed at one side of the frame <NUM>, the cell holders <NUM> may be coupled to a lower portion of the frame <NUM> while the cell holders <NUM> are stacked in a vertical direction. When the cell holders <NUM> are stacked, the insertion holes B formed in the cell holders <NUM> may communicate each other to have an increased vertical length. Thus, a portion of the battery cells <NUM>, which is inserted to the insertion holes B communicating each other, may be increased, and a portion of the battery cells <NUM>, which is disposed in the inner space of the frame <NUM>, may be decreased. Thus, a volume of the inner space of the frame <NUM> may be decreased by decreasing the vertical length of the frame <NUM> as many as the number of the provided cell holders <NUM>.

For example, when the number of the provided cell holders <NUM> is increased, the volume of the inner space of the frame <NUM> may be decreased, and when the number of the provided cell holders <NUM> is decreased, the volume of the inner space of the frame <NUM> may be increased. Thus, when the volume of the inner space of the frame <NUM> is decreased, the amount of the filling material <NUM> filled in the inner space of the frame <NUM> may be decreased, and when the volume of the inner space of the frame <NUM> is increased, the amount of the filling material <NUM> filled in the inner space of the frame <NUM> may be increased. Thus, the usage amount of the filling material <NUM> may be adjusted by setting the number or height of the stacked cell holders <NUM>.

Thereafter, the filling material <NUM> may be injected to the rest space in which the supports <NUM> are not installed in the space between the battery cells <NUM>. Thus, the filling material <NUM> may be supplied between the battery cells <NUM> to hold the upper end of the battery cells <NUM>.

Here, the volume of the inner space of the frame <NUM> is decreased by the cell holders <NUM>, and the supports <NUM> are installed in the inner space of the frame <NUM> in advance. Thus, the usage amount of the filling material <NUM> supplied to fill the empty space between the battery cells <NUM> may be decreased by decreasing the volume of the empty space between the battery cells <NUM> twice. When the usage amount of the filling material <NUM> is decreased, a time and costs required to fill the filling material <NUM> may be decreased. That is, since the filling material <NUM> is not filled in a space in which the cell holders <NUM> are stacked and a space in which the supports <NUM> are not installed, the usage amount of the filling material <NUM> may be adjusted according to the stacked number or of the cell holders <NUM> set based on a design specification of a battery pack <NUM> or according to the number of the provided supports <NUM>.

Also, when a gap exists between the battery cells <NUM> and the supports <NUM>, the filling material <NUM> may surround perimeters of the supports <NUM> and the battery cells <NUM> when the filling material <NUM> is injected. Thus, the filling material <NUM> may directly or indirectly contact the battery cells <NUM> through the filling material <NUM>. Thus, although the gap exists between the battery cells <NUM> and the supports <NUM>, the supports <NUM> may support the battery cells <NUM>.

Here, a material of the filling material <NUM> may include silicon. Thus, although the feature of filling the filling material <NUM> into the space between the battery cells requires much time and costs, the usage amount of the filling material <NUM> may be decreased by including the cell holder <NUM> and the supports <NUM> as described above. Thus, an efficiency of a process of manufacturing the battery pack <NUM> may be improved.

Claim 1:
A battery pack (<NUM>) comprising:
a frame (<NUM>) having an inner space and an opened one side;
a plurality of battery cells (<NUM>) each having one end disposed in the inner space of the frame (<NUM>) and the other end protruding to the outside of one side of the frame (<NUM>);
a cell holder (<NUM>) having a plurality of insertion holes to which the other ends of the battery cells (<NUM>) are respectively inserted and installed at one side of the frame (<NUM>);
a heat sink (<NUM>) installed on the cell holder (<NUM>) to cool the battery cells (<NUM>);
a plurality of supports (<NUM>) disposed in a portion of a space between the battery cells (<NUM>); and
a filling material (<NUM>) filled in the rest space in which the supports (<NUM>) are not disposed in the space between the battery cells (<NUM>),
wherein a filled amount of the filling material (<NUM>) is adjusted according to the number of the provided supports (<NUM>),
wherein the cell holder (<NUM>) is provided in plurality, and a plurality of cell holders are stacked in a vertical direction.