Battery pack and method for assembling the battery pack
The battery pack design addresses heat dissipation and welding challenges by incorporating interconnectors with a connection structure and spaces for heat and gas release, resulting in improved reliability and reduced costs.
Patent Information
- Application Number
- JP2024556812
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-03-26
- Filing Date
- 2023-03-06
- Publication Date
- 2025-04-14
AI Technical Summary
Existing battery packs face challenges with heat dissipation and welding defects due to the generation of heat during charging and discharging, and the complexity of connecting non-insulated battery cells, which can lead to reduced capacity, short circuits, and increased manufacturing and operating costs.
The battery pack design includes a plurality of battery cells, upper and lower holders, and top and bottom plates with interconnectors that have a connection structure allowing contact with the positive terminal of the battery cell, and a space for heat dissipation and gas release, facilitating easier welding and reducing the risk of short circuits.
This design enhances heat dissipation and gas release, improves access for welding, reduces the risk of short circuits, and increases the pull-off strength of the welding connections, thereby extending the life of the battery pack and reducing manufacturing and operating costs.
Smart Images
Figure 2025510272000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to a battery pack and a method for assembling a battery pack. More particularly, the present invention relates to an interconnect within a battery pack. [Background technology]
[0002] A battery pack is a set of multiple battery cells connected in series, parallel, or a combination of series and parallel to achieve a desired voltage, capacity, or power density, and includes interconnects that provide electrical conductivity between the multiple battery cells.
[0003] Battery cells, especially non-insulated battery cells, and other components in the battery pack generate heat during operation of the battery pack, i.e., both during the charging process for energy storage and during the discharging process in which energy is consumed. Also, when a battery cell fails in the battery pack, e.g., by a short circuit, hot gas is released, which generates heat. The heat generated in the battery pack during the charging / discharging process and / or the release of hot gas due to a battery cell failure can adversely affect the integrity of the battery cells in the battery pack and can cause serious damage to the functional cells of the battery pack. Moreover, this is undesirable, as it will also adversely affect the lifespan of the battery pack.
[0004] Furthermore, connecting multiple battery cells together in a battery pack by utilizing welding is difficult and costly. Intricate weld patterns need to be created to minimize the possibility of weld failure. Weld defects result in reduced capacity, short circuits, and possible heating at the weld joint failure. The higher the number of cells in a battery pack, the higher the risk of failure of the battery pack. This is undesirable as it leads to increased manufacturing and operating costs of the battery pack.
[0005] Furthermore, when multiple non-insulated battery cells are placed in a cell holder, the cell holder insulates the negative terminals of the battery cells, which can create gaps between the positive terminals and the interconnects, making it difficult to weld the interconnects to the positive terminals of the battery cells. Summary of the Invention [Problem to be solved by the invention]
[0006] In view of the above, it is believed that there is a need to overcome the above-mentioned shortcomings. [Means for solving the problem]
[0007] In one aspect, a battery pack is disclosed that includes a plurality of battery cells, one or more top holders, one or more bottom holders, one or more top plates, and one or more bottom plates. Each of the plurality of battery cells includes a positive terminal and a negative terminal. The one or more top holders and the one or more bottom holders are configured to receive end portions of the plurality of battery cells. The one or more top plates are disposed on the one or more top holders. The one or more bottom plates are disposed on the one or more bottom holders. Each of the one or more top plates and the one or more bottom plates includes a plurality of interconnectors. Each of the plurality of interconnectors includes a hole and a connection structure extending from the hole to enable contact with a positive terminal of the battery cell.
[0008] In one embodiment, the connection structure includes a first member extending in a direction toward the battery cell and a second member extending from the first member in a direction parallel to the longitudinal axis of the battery pack.
[0009] In one embodiment, the connection structure includes a first member extending in a direction toward the battery cell and a second member extending from the first member in a direction parallel to the transverse axis of the battery pack.
[0010] In one embodiment, the plurality of battery cells are non-isolated cells.
[0011] In one embodiment, a space is provided between the second member of each of the multiple interconnects and each of the one or more top / bottom plates for venting gases and dissipating heat from the battery pack.
[0012] In one embodiment, each of the one or more top plates and the one or more bottom plates includes a flat portion between the plurality of interconnectors, the flat portion being in contact with the negative terminals of the plurality of battery cells.
[0013] In one embodiment, the second member of the connection structure is welded to the positive terminal of the battery cell.
[0014] In another aspect of the present invention, a method of assembling a battery pack is disclosed that includes a plurality of battery cells, one or more upper holders, one or more lower holders, one or more upper plates, and one or more lower plates. The method includes disposing end portions of the plurality of battery cells in the one or more upper holders and the one or more lower holders. Each of the plurality of battery cells includes a positive terminal and a negative terminal. The method further includes disposing the one or more upper plates on the one or more upper holders and disposing the one or more lower plates on the one or more lower holders. Each of the one or more upper plates and the one or more lower plates includes a plurality of interconnectors. Each of the plurality of interconnectors includes a hole and a connection structure extending from the hole to allow contact with the positive terminal of the battery cell. The method further includes connecting the connection structure of the plurality of interconnectors to the positive terminal of the plurality of battery cells. In one non-limiting example, the plurality of interconnectors are connected to the positive terminal of the plurality of battery cells by welding.
[0015] Reference will be made to embodiments of the invention, examples of which may be illustrated in the accompanying drawings, which are intended to be illustrative, and not limiting, and while the invention will be broadly described in the context of these embodiments, it will be understood that it is not intended to limit the scope of the invention to these particular embodiments. [Brief description of the drawings]
[0016] [Figure 1] 1 is a perspective view of a battery pack according to an embodiment of the present invention; FIG. [Diagram 2] FIG. 2 is an exploded view of a battery pack according to one embodiment of the present invention. [Diagram 3] FIG. 2 is an exploded view of a battery pack according to one embodiment of the present invention. [Figure 4]FIG. 2 illustrates a perspective view of a top plate and a bottom plate with multiple interconnects according to one embodiment of the present invention. [Diagram 5] 1 is a cross-sectional view of an interconnector showing a connection structure according to one embodiment of the present invention. [Figure 6] FIG. 2 is a cross-sectional view of a battery pack illustrating the connection of a battery cell to an interconnector according to one embodiment of the present invention. [Figure 7] 2 is a flow diagram of a method for assembling a battery pack according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Various features and embodiments of the present invention will become apparent from the further description of the invention that follows.
[0018] Fig. 1 is a perspective view of a battery pack 100 according to an embodiment of the present invention. Fig. 2 is a cross-sectional view of the battery pack 100 according to an embodiment of the present invention. Fig. 3 is an exploded view of the battery pack 100 according to an embodiment of the present invention.
[0019] As shown, the battery pack 100 includes a plurality of battery cells 102, one or more upper holders 104, one or more lower holders 106, one or more upper plates 108, and one or more lower plates 110. Further shown in Figure 3 is a longitudinal axis AA and a transverse axis BB of the battery pack 100.
[0020] The plurality of battery cells 102 may be conventional battery cells that convert chemical energy of materials stored in the battery cells into electrical energy. Each of the plurality of battery cells 102 includes a first end 102a and a second end 102b. Each of the plurality of battery cells 102 includes a positive terminal and a negative terminal. Preferably, the positive terminal protrudes from the first end 102a of the battery cell 102. Preferably, the negative terminal starts from the second end 102b of the battery cell 102, continues on the outer surface of the battery cell 102, and covers at least a portion of the first end 102a of the battery cell 102. The end portion of each cell of the plurality of battery cells 102 is a portion near the first end 102a and the second end 102b of the battery cell 102. In other words, the first end portion is the area near the first end 102a of the battery cell 102, and the second end portion is the area near the second end 102b of the battery cell 102. The battery cell 102 may be insulated or uninsulated.
[0021] The one or more top holders 104 and the one or more bottom holders 106 are configured to receive end portions of the battery cells 102. Each of the one or more top holders 104 and the one or more bottom holders 106 may be a box-shaped housing with a means for receiving the battery cells in an upright position. In one non-limiting example, each of the one or more top holders and the one or more bottom holders includes a bottom and four side walls supported on the bottom. The side walls may be attached to the bottom via any suitable joining means, such as fasteners. The side walls may also be integrally formed with the bottom. The bottom may include slots or any other such means for accurately positioning the end portions of the battery cells.
[0022] 3, the plurality of battery cells 102 consists of a first set of battery cells 118 and a second set of battery cells 120. A first end portion of each of the first set of battery cells 118 is received within the one or more upper holders 104, and a second end portion of each of the first set of battery cells 118 is received within the one or more lower holders 106. A first end portion of each of the second set of battery cells 120 is received within the one or more lower holders 106, and a second end portion of each of the second set of battery cells 120 is received within the one or more upper holders 104.
[0023] The one or more top plates 108 are disposed on the one or more top holders 104, and the one or more bottom plates 110 are disposed on the one or more bottom holders 106. Each of the one or more top plates 108 and the one or more bottom plates 110 includes a plurality of interconnectors 122. As shown in FIG. 6 , each interconnector 122 has a hole 124 and a connection structure 126 extending from the hole 124 to enable contact with a positive terminal of a battery cell 102.
[0024] In one embodiment, the connection structure 126 includes a first member 126a extending in a direction toward the battery cells 102 and a second member 126b extending from the first member 126a in a direction parallel to the longitudinal axis AA of the battery pack 100. In one non-limiting example, the connection structure 126 is an L-shaped member and the first member 126a is a straight member. In another non-limiting example, the first member is an angled member.
[0025] In one embodiment, the connection structure 126 includes a first member 126a extending in a direction toward the battery cells 102 and a second member 126b extending from the first member 126a in a direction parallel to the transverse axis BB of the battery pack 100. In one non-limiting example, the connection structure 126 is an L-shaped member and the first member 126a is a straight member. In another non-limiting example, the first member is an angled member.
[0026] In one embodiment, the plurality of battery cells 102 are non-isolated cells.
[0027] In one embodiment, a space 128 (see FIG. 5) for venting gases and dissipating heat from the battery pack 100 is provided between the second member 126b of each of the multiple interconnectors and each of the one or more upper / lower plates 108, 110.
[0028] In one embodiment, the one or more top plates 108 and the one or more bottom plates 110 each include flat portions 130 between the plurality of interconnects 122. These flat portions 130 are in contact with the negative terminals of the plurality of battery cells 102.
[0029] In one embodiment, the second member 126b of the connection structure 126 is welded to the positive terminal of the battery cell 102.
[0030] Figure 4 shows a perspective view of the top plate 108 and bottom plate 110 with multiple interconnects 122 according to one embodiment of the invention. Figure 5 shows a cross-sectional view of the interconnect 122 showing a connection structure 126 according to one embodiment of the invention.
[0031] As shown, the top plate 108 and the bottom plate 110 of the battery pack 100 include a plurality of interconnectors 122. Each of the plurality of interconnectors 122 has a hole 124 and a connection structure 126 extending from the hole 124 to enable contact with the positive terminal of a battery cell 102.
[0032] Additionally, as shown, a space 128 for venting gases and dissipating heat from the battery pack 100 is provided between the second member 126b of each of the plurality of interconnectors 122 and each of the one or more top / bottom plates 108, 110. Each of the one or more top plates 108 and the one or more bottom plates 110 includes flat portions 130 between the plurality of interconnectors 122. These flat portions 130 are in contact with the negative terminals of the plurality of battery cells 102.
[0033] In one embodiment, the connection structure 126 comprises a first member 126a extending in a direction toward the battery cells 102 and a second member 126b extending from the first member 126a in a direction parallel to the longitudinal axis AA of the battery pack 100. In one non-limiting example, the connection structure 126 is an L-shaped member and the first member 126a is a straight member. In another non-limiting example, the first member is an angled member.
[0034] In one embodiment, the connection structure 126 comprises a first member 126a extending in a direction toward the battery cells 102 and a second member 126b extending from the first member 126a in a direction parallel to the transverse axis BB of the battery pack 100. In one non-limiting example, the connection structure 126 is an L-shaped member and the first member 126a is a straight member. In another non-limiting example, the first member is an angled member.
[0035] FIG. 6 is a cross-sectional view of a battery pack illustrating the connection of a battery cell 102 to an interconnect 122 according to one embodiment of the present invention.
[0036] The dashed circles C and D indicate the connection of the interconnector 122 to the positive terminal of the battery cell 102. In one non-limiting example, the second member 126b of the connection structure 126 is welded to the positive terminal of the battery cell 102.
[0037] FIG. 7 illustrates a flow diagram of a method 700 for assembling a battery pack 100 according to one embodiment of the present invention.
[0038] The method includes, at step 701, placing end portions of a plurality of battery cells 102 in one or more upper holders 104 and one or more lower holders 106. Each battery cell 102 of the plurality of battery cells 102 includes a positive terminal and a negative terminal.
[0039] The method includes, at step 702, disposing one or more top plates 108 on one or more top holders 104 and disposing one or more bottom plates 110 on one or more bottom holders 106. The one or more top plates 108 and the one or more bottom plates 110 each include a plurality of interconnects 122. Each of the plurality of interconnects 122 includes a hole 124 and a connection structure 126. The connection structure extends from the hole 124 to enable contact with a positive terminal of a battery cell 102.
[0040] The method includes, at step 703, welding the connection structures 126 of the plurality of interconnectors 122 to the positive terminals of the plurality of battery cells 102. In one non-limiting example, the plurality of interconnectors are connected to the positive terminals of the plurality of battery cells by welding.
[0041] The claimed features / steps of the present invention as discussed above are not conventional, conventional, or well understood in the art, and these claimed steps provide solutions to the existing problems in the prior art: Specifically, the technical problems of dissipating heat from the battery pack 100 during charging / discharging of the battery pack 100, the difficulty of welding the battery cells 102 to the interconnects 122 due to problems such as cell float and short circuit, and improper insulation of the battery pack 100 having non-insulated battery cells 102 are eliminated by the present invention.
[0042] The present invention allows better access to the battery cell 102 for welding. The second member 126b of the connection structure 126 allows better access to the positive terminal of the battery cell 102 during welding. When a gap occurs between the top plate 108 and the positive terminal of the battery cell 102, the second member 126 of the connection structure 126 can be pressed to reach the positive terminal of the battery cell 102 for better welding. In other words, the present invention provides room to adjust the cell float by using the second member 126b of the interconnector 122 during welding. Furthermore, the pull-out strength of the weld is improved by the present invention.
[0043] Additionally, the space between the top plate 108 / bottom plate 110 and the second member 126b allows for the escape of hot gases from the battery pack 100 that may occur during a battery cell failure or dissipation of heat during charging / discharging of the battery pack, especially in the case of a battery pack 100 having non-insulated battery cells 102.
[0044] Additionally, the second member 126b of the interconnect also allows for a connection between the battery cells 102 and the interconnect 122 without risk of short circuiting. This is especially true for battery packs 100 having non-insulated battery cells 102.
[0045] Furthermore, in the battery pack 100 having the non-insulated battery cell 102, the upper holder 104 and the lower holder 106 insulate the negative terminal of the battery cell 102, which may cause a gap between the positive terminal of the battery cell 102 and the interconnector 122. The second member 126b of the connection structure 126 of the interconnector 122 in the present invention eliminates this problem and allows a better connection to be obtained between the positive terminal of the battery cell 102 and the interconnector 122.
[0046] Although the present invention has been described with reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the scope of the invention as defined in the appended claims. [Explanation of symbols]
[0047] 100 Battery Packs 102 Battery Cell 102a First end 102b Second end 104 Upper holder 106 Lower Holder 108 Top Plate 110 Lower Plate 118 First set of battery cells 120 Second Battery Cell Set 122 Interconnector 124 holes 126 Connection Structure 126a First member 126b Second member 128 Space 130 Flat part AA Longitudinal axis
Claims
1. a plurality of battery cells (102) each having a positive terminal and a negative terminal; one or more upper holders (104) and one or more lower holders (106) configured to receive end portions of the plurality of battery cells (102); one or more upper plates (108) disposed on the one or more upper holders (104) and one or more lower plates (110) disposed on the one or more lower holders (106), each of the one or more upper plates (108) and the one or more lower plates (110) having a plurality of interconnectors (122), each of the plurality of interconnectors (122) having a hole (124) and a connection structure (126) extending from the hole (124) to enable contact with the positive terminal of the battery cell (102); A battery pack (100).
2. 2. The battery pack (100) of claim 1, wherein the connection structure (126) comprises a first member (126a) extending in a direction toward the battery cell (102) and a second member (126b) extending from the first member (126a) in a direction parallel to a longitudinal axis (A-A) of the battery pack (100).
3. 2. The battery pack (100) of claim 1, wherein the connection structure (126) comprises a first member (126a) extending in a direction toward the battery cells (102) and a second member (126b) extending from the first member (126a) in a direction parallel to a transverse axis (B-B) of the battery pack (100).
4. The battery pack (100) of claim 1, wherein the plurality of battery cells (102) are non-isolated cells.
5. 3. The battery pack (100) of claim 2, wherein a space (128) for venting gases and dissipating heat from the battery pack (100) is provided between the second member (126b) of each of the plurality of interconnectors (122) and each of the one or more top / bottom plates (108, 110).
6. 2. The battery pack (100) of claim 1, wherein each of the one or more upper plates (108) and the one or more lower plates (110) comprises a flat portion (130) between the plurality of interconnectors (122), the flat portion (130) being in contact with the negative terminals of the plurality of battery cells (102).
7. 4. The battery pack (100) of claim 1, wherein the second member (126b) of the connection structure (126) is welded to the positive terminal of the battery cell (102).
8. A method of assembling a battery pack (100), comprising: placing end portions of a plurality of battery cells (102) in one or more upper holders (104) and one or more lower holders (106), each of the plurality of battery cells (102) having a positive terminal and a negative terminal; placing one or more upper plates (108) on the one or more upper holders (104) and one or more lower plates (110) on the one or more lower holders (106), wherein each of the one or more upper plates (108) and the one or more lower plates (110) has a plurality of interconnects (122), each of the plurality of interconnects (122) having a hole (124) and a connection structure (126) extending from the hole (124) to enable contact with the positive terminal of the battery cell (102); connecting the connection structures (126) of the plurality of interconnectors (122) to the positive terminals of the plurality of battery cells (102); A method comprising:
9. 10. The method of assembling the battery pack (100) of claim 8, wherein the plurality of interconnectors (122) are connected to the positive terminals of the plurality of battery cells (102) by welding.