Battery pack and battery pack assembly method

Abstract

According to exemplary embodiments of the present invention, a battery pack is provided. The battery pack comprises: a lower frame comprising a base plate, a first side plate connected to a first side of the base plate, and a second side plate connected to a second side of the base plate; and a first battery assembly and a second battery assembly disposed on the base plate, wherein each of the first battery assembly and the second battery assembly comprises a cell stack that includes a plurality of battery cells, and a first cross beam that is coupled to a first side of the cell stack.

Description

Battery pack and battery pack assembly method

[0001] The present invention relates to a battery pack and a method for assembling a battery pack, and more particularly, to a battery pack and a method for assembling a battery pack that enhances assembly convenience and processability. This application claims the benefit of Korean Application No. 10-2023-0095119, filed July 21, 2023, which is incorporated herein by reference in its entirety.

[0002] Secondary batteries can be charged and discharged multiple times and are used as an energy source for various electronic devices. As technology advances, secondary batteries are being used not only in portable devices but also in mobility devices such as electric vehicles (EVs) and hybrid electric vehicles (HEVs), in the form of battery modules or battery packs.

[0003] Battery packs can be manufactured by assembling multiple battery assemblies and various components surrounding them. The proper placement of these components can significantly impact quality stability and manufacturing speed. For example, if the assembly accuracy of a battery pack is low, the likelihood of errors occurring during the manufacturing process increases, potentially leading to deterioration in quality. Accordingly, various studies are being conducted to improve the assembly accuracy of battery packs.

[0004] Accordingly, the first technical idea of ​​the present invention aims to solve a problem by providing a battery pack with improved assembly efficiency. The second technical idea of ​​the present invention aims to solve a problem by providing a battery pack assembly method with improved assembly efficiency.

[0005] According to exemplary embodiments of the present invention for solving the first problem described above, a battery pack is provided. The battery pack includes a lower frame including a base plate, a first side plate connected to a first side of the base plate, and a second side plate connected to a second side of the base plate; and a first battery assembly and a second battery assembly disposed on the base plate, each of the first battery assembly and the second battery assembly including a cell stack including a plurality of battery cells and a first cross beam connected to a first side of the cell stack, the first cross beam having a first step structure including a first coupling surface, a second coupling surface, and a third coupling surface sequentially connected, and the first cross beam is characterized in that it includes a first groove recessed into the second coupling surface.

[0006] In an exemplary embodiment, the second bonding surface is parallel to the upper surface of the base plate, the first bonding surface is perpendicular to the second bonding surface, and the third bonding surface is perpendicular to the second bonding surface.

[0007] In an exemplary embodiment, the first side plate includes a protruding structure inserted into the first groove, the protruding structure being characterized in that it extends in a first direction parallel to the upper surface of the base plate.

[0008] In an exemplary embodiment, the battery pack is characterized in that each of the first battery assembly and the second battery assemblies further includes a second cross beam coupled to the second side of the cell stack, the second side being opposite the first side, the second cross beam having a second stepped structure including a fourth coupling surface, a fifth coupling surface, and a sixth coupling surface sequentially connected, the fifth coupling surface including a second groove recessed inwardly and a handle partially embedded in the second groove, and the handle is configured to rotate.

[0009] In an exemplary embodiment, the rotation axis of the handle is embedded in the second groove, and the rotation axis is characterized in that it is parallel to the first direction which is parallel to the upper surface of the base plate.

[0010] In an exemplary embodiment, the rotation axis of the handle is characterized in that it is parallel to the fourth engagement surface.

[0011] In an exemplary embodiment, the fifth bonding surface is parallel to the upper surface of the base plate, the fourth bonding surface is perpendicular to the fifth bonding surface, and the sixth bonding surface is perpendicular to the fifth bonding surface.

[0012] In an exemplary embodiment, the fifth joining surface of the second cross beam of the first battery assembly is characterized in that it contacts the second joining surface of the first cross beam of the second battery assembly.

[0013] In an exemplary embodiment, the fourth joining surface of the second cross beam of the first battery assembly is in contact with the first joining surface of the first cross beam of the second battery assembly, and the sixth joining surface of the second cross beam of the first battery assembly is in contact with the third joining surface of the first cross beam of the second battery assembly.

[0014] In an exemplary embodiment, the height of the handle of the second cross beam is characterized by being equal to or smaller than the depth of the first groove of the first cross beam.

[0015] In an exemplary embodiment, the handle is hinged to the second groove, wherein the depth of the second groove is equal to or greater than the thickness of the handle.

[0016] In an exemplary embodiment, the battery pack comprises a lower frame including a base plate; and first and second battery assemblies disposed on the base plate, each of the first and second battery assemblies including a cell stack including a plurality of battery cells, a first cross beam coupled to a first side of the cell stack, and a second cross beam coupled to a second side of the cell stack, the second side being opposite the first side, the first cross beam including a plurality of first grooves recessed inwardly, and the second cross beam including a plurality of second grooves recessed inwardly and a plurality of handles, each of the plurality of handles being partially embedded in a corresponding one of the plurality of second grooves.

[0017] In an exemplary embodiment, each of the plurality of handles of the second cross beam is coupled to a corresponding one of the plurality of first grooves of the first cross beam, the handle being configured to be rotatable by a rotational axis, and the rotational axis being embedded in the second groove and being parallel to the first direction which is parallel to the upper surface of the base plate.

[0018] Meanwhile, according to exemplary embodiments of the present invention for solving the second problem described above, a method for assembling a battery pack is provided. The method for assembling a battery pack may include the steps of: providing first and second battery assemblies, each of the first and second battery assemblies including a cell stack and first and second cross beams coupled to the cell stack; placing the first battery assembly on a base plate of a lower frame; and placing the second battery assembly on the base plate, wherein a handle of a second cross beam of the first battery assembly is coupled to a first groove of a first cross beam of the second battery assembly. In this case, the lower frame is characterized in that it includes a base plate, a first side plate coupled to a first side of the base plate, and a second side plate coupled to a second side of the base plate, and the first cross beam includes a first groove, the second cross beam includes a second groove, and a handle hinged to the second groove.

[0019] In an exemplary embodiment, the first battery assembly is characterized by being placed on the base plate using the first groove of the first cross beam and the handle of the second cross beam.

[0020] In an exemplary embodiment, the first side plate includes a protruding structure that engages with the first groove, and when the first battery assembly is placed on the base plate of the lower frame, the first groove of the first cross beam and the protruding structure of the first side plate engage with each other.

[0021] A battery pack according to exemplary embodiments of the present invention includes a first cross beam and a second cross beam coupled to a cell stack. The first cross beam includes a first groove, and the second cross beam includes a handle engageable with the first groove. The first groove and the handle can improve the engageability and mobility of the first cross beam and the second cross beam. Accordingly, the assembly efficiency of the battery pack and the battery pack assembly method can be improved.

[0022] The effects that can be obtained from the exemplary embodiments of the present invention are not limited to the effects mentioned above, and other effects that are not mentioned can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of the present disclosure pertain from the following description. In other words, unintended effects that arise from practicing the exemplary embodiments of the present disclosure can also be derived by those skilled in the art from the exemplary embodiments of the present disclosure.

[0023] FIG. 1 is a perspective view illustrating a battery pack according to exemplary embodiments.

[0024] Figure 2 is a cross-sectional view taken along the cutting line AA´ of Figure 1.

[0025] FIG. 3 is a perspective view showing a first cross beam according to exemplary embodiments.

[0026] FIG. 4 is a perspective view showing a second cross beam according to exemplary embodiments.

[0027] FIG. 5 is a perspective view showing a second cross beam having a handle housed therein according to exemplary embodiments.

[0028] Figure 6 is an enlarged partial cross-sectional view of part (B) of Figure 2.

[0029] FIG. 7 is a cross-sectional view showing a battery pack according to exemplary embodiments.

[0030] FIG. 8 is a cross-sectional view showing a battery pack according to exemplary embodiments.

[0031] FIG. 9 is a flowchart illustrating a battery pack assembly method according to exemplary embodiments.

[0032] FIG. 10 is a cross-sectional view of a first cross beam and a second cross beam according to exemplary embodiments.

[0033] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, it should be noted that the terms and words used in this specification and claims should not be construed as limited to their conventional or dictionary meanings. Based on the principle that the inventor can appropriately define the concepts of terms to best explain his or her invention, they should be interpreted in a way that aligns with the technical spirit of the present invention.

[0034] Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that there may be various equivalents and modified examples that can replace them at the time of filing this application.

[0035] In addition, when describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description is omitted.

[0036] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or schematically illustrated for clearer explanation. Accordingly, the sizes and proportions of each component do not fully reflect the actual sizes or proportions.

[0037]

[0038] battery pack

[0039] (Example 1)

[0040]

[0041] FIG. 1 is a perspective view showing a battery pack (100) according to exemplary embodiments.

[0042] Figure 2 is a side view taken along the cutting line AA´ of Figure 1.

[0043] Referring to FIGS. 1 and 2, a battery pack (100) may include a lower frame (110) and a plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6). The lower frame (110) may support components included in the battery pack (100). The lower frame (110) may provide a space for mounting the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6). The lower frame (110) may include a base plate (110B), a first side plate (110S1) connected to a first side of the base plate (110B), and a second side plate (110S2) connected to a second side of the base plate (110B). For example, the lower frame (110) can be formed integrally.

[0044] Two directions substantially parallel to the upper surface (110BU) of the base plate (110B) are defined as the X direction and the Y direction, respectively, and a direction substantially perpendicular to the upper surface of the base plate (110B) is defined as the Z direction. The X direction, the Y direction, and the Z direction may be substantially perpendicular to each other. The Y direction may be referred to as a first direction. The X direction may be referred to as a second direction. The Z direction may be referred to as a third direction. Unless otherwise stated, the definitions of directions are the same for the drawings below.

[0045] The base plate (110B) can support a plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6). A plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) can be arranged on the upper surface (110BU) of the base plate (110B).

[0046] The base plate (110B) may be configured to cool a plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6). The base plate (110B) may include a plurality of cooling channels. The plurality of cooling channels may extend in the Y direction.

[0047] The side plates (110S1, 110S2) may be connected to the base plate (110B). The side plates (110S1, 110S2) may extend in the Z direction from the upper surface (110BU) of the base plate (110B). The side plates (110S1, 110S2) may be substantially perpendicular to the Y direction. A space in which a plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) are mounted may be provided by the side plates (110S1, 110S2) and the base plate (110B). The side plate (110S1) may be referred to as a first side plate, and the side plate (110S2) may be referred to as a second side plate.

[0048] The first side plate (110S1) can be connected to the first side of the base plate (110B). The second side plate (110S2) can be connected to the second side of the base plate (110B). The first side plate (110S1) and the second side plate (110S2) can be parallel to each other. The first side plate (110S1) and the second side plate (110S2) can be spaced apart from each other in the Y direction.

[0049] The battery pack (100) may be the final form of a battery system mounted on a mobility device, etc. According to exemplary embodiments, the battery pack (100) may be of a module type, in which case each of the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) may include a module frame. According to exemplary embodiments, the battery pack (100) may be of a moduleless type, in which case each of the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) may not include a module frame.

[0050] In an exemplary embodiment, each of the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) may include a cell stack (121) including a plurality of battery cells and a first cross beam (122). In an exemplary embodiment, each of the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) may include a cell stack (121) including a plurality of battery cells, a first cross beam (122), and a second cross beam (123). The battery cell is a basic unit of a lithium ion battery, i.e., a secondary battery. Each of the plurality of battery cells includes an electrode assembly, an electrolyte, and a case. Each of the plurality of battery cells may be classified into a lithium ion battery, a lithium ion polymer battery, a lithium polymer battery, etc., depending on the configuration of the electrode assembly and the electrolyte. Each of the plurality of battery cells may be any one of a cylindrical battery cell, a square battery cell, and a pouch-type battery cell.

[0051] A plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) can be arranged in the X direction and the Y direction. In FIG. 1, the lower frame (110) can provide a space in which two battery assemblies are arranged in the X direction and three battery assemblies are arranged in the Y direction (3x2 arrangement). In addition, the number of the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) is not limited to six, and the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) can be arranged in an MxN (M and N are integers greater than or equal to 2) arrangement in addition to the 3x2 arrangement.

[0052] Battery assembly (120_1) may be referred to as a first battery assembly, battery assembly (120_2) may be referred to as a second battery assembly, battery assembly (120_3) may be referred to as a third battery assembly, battery assembly (120_4) may be referred to as a fourth battery assembly, battery assembly (120_5) may be referred to as a fifth battery assembly, and battery assembly (120_6) may be referred to as a sixth battery assembly.

[0053] In an exemplary embodiment, each of the first to third battery assemblies (120_1, 120_2, 120_3) may be arranged in the X direction, and each of the fourth to sixth battery assemblies (120_4, 120_5, 120_6) may be arranged in the X direction. In an exemplary embodiment, each of the first and fourth battery assemblies (120_1, 120_4) may be spaced apart from each other in the Y direction, each of the second and fifth battery assemblies (120_2, 120_5) may be spaced apart from each other in the Y direction, and each of the third and sixth battery assemblies (120_3, 120_6) may be spaced apart from each other in the Y direction.

[0054] In an exemplary embodiment, each of the first battery assembly (120_1), the second battery assembly (120_2), the fourth battery assembly (120_4), and the fifth battery assembly (120_5) may include a cell stack (121) including a plurality of battery cells and a first cross beam (122) coupled to a first side (121S1) of the cell stack (121). In an exemplary embodiment, each of the first battery assembly (120_1) and the second battery assembly (120_2) may include a cell stack (121), a first cross beam (122) coupled to a first side (121S1) of the cell stack (121), and a second cross beam (123) coupled to a second side (121S2) of the cell stack (121).

[0055] The first cross beam (122) and the second cross beam (123) can be placed on the base plate (110B) of the lower frame (110). The first and second cross beams (122, 123) can extend in the Y direction. The first and second cross beams (122, 123) can be coupled to the base plate (110B).

[0056] In an exemplary embodiment, the first cross beam (122) may be disposed on a first side (121S1) of the cell stack (121), and the second cross beam (123) may be disposed on a second side (121S2) of the cell stack (121). Accordingly, the cell stack (121) may be transported using the first cross beam (122) and the second cross beam (123) without directly holding the cell stack (121). Accordingly, damage to the cell stack (121) may be prevented during the assembly process of the battery pack (100), and thus the yield and safety of the battery pack (100) may be improved.

[0057] In an exemplary embodiment, the first cross beam (122) of the first battery cell assembly (120_1) may be interposed between the first side plate (110S1) and the cell stack (121). In an exemplary embodiment, the first cross beam (122) of the second battery cell assembly (120_2) may be interposed between the second cross beam (123) of the first battery cell assembly (120_1) and the cell stack (121) of the second battery cell assembly (120_2). The second cross beam (123) of the second battery cell assembly (120_2) may be interposed between the first cross beam (122) of the third battery cell assembly (120_3) and the cell stack (121) of the second battery cell assembly (120_2).

[0058] The first cross beam (122) of each of the battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) can be coupled with the second cross beam (123) of the preceding battery cell assemblies. In an exemplary embodiment, the second cross beam (123) of the first battery assembly (120_1) can be coupled with the first cross beam of the adjacent second battery assembly (120_2). In an exemplary embodiment, the second cross beam (123) of the second battery assembly (120_2) can be coupled with the first cross beam of the adjacent third battery assembly (120_3). In an exemplary embodiment, the second cross beam (123) of the fourth battery assembly (120_4) can be coupled with the first cross beam of the adjacent fifth battery assembly (120_5). In an exemplary embodiment, the second cross beam (123) of the fifth battery assembly (120_5) can be coupled with the first cross beam of the adjacent sixth battery assembly (120_6). The first and second cross beams (122, 123) can connect adjacent ones among the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6). Accordingly, a plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) can be sequentially arranged on the base plate (110B), so that the assembly of the plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) with respect to the lower frame (110) can be improved.

[0059] In an exemplary embodiment, the third battery assembly (120_3) and the sixth battery assembly (120_6) may include a first cross beam (122) coupled to a first side (121S1) of the cell stack (121). The second side (121S2) of the cell stack (121) of each of the third and sixth battery assemblies (120_3, 120_6) may be in contact with the second side plate (110S2). Through this, the first cross beam (122) of the third battery assembly (120_3) may be coupled to the second cross beam (123) of the second battery assembly (120_2). The first cross beam (122) of the sixth battery assembly (120_6) may be coupled to the second cross beam (123) of the fifth battery assembly (120_5). Accordingly, the stability and space utilization rate of the battery pack (100) can be improved.

[0060]

[0061] FIG. 3 is a perspective view showing a first cross beam (122) according to exemplary embodiments.

[0062] FIG. 4 is a perspective view showing a second cross beam (123) according to exemplary embodiments.

[0063] FIG. 5 is a perspective view showing a folded second cross beam (123) with a handle (123H) according to exemplary embodiments.

[0064] Referring to FIGS. 2 to 5, the first cross beam (122) may include a first upper surface (122U) and a first lower surface (122D). The first upper surface (122U) and the first lower surface (122D) may be substantially parallel to the base plate upper surface (110BU). The first lower surface (122D) may be in contact with the base plate (110B), and the first upper surface (122U) may be located on the opposite side of the first lower surface (122D).

[0065] The first cross beam (122) may include a first step structure (122C) including a first coupling surface (122C1), a second coupling surface (122C2), and a third coupling surface (122C3) that are sequentially connected. For example, the first upper surface (122U) may be connected to the first coupling surface (122C1), and the first coupling surface (122C1) may be connected to the second coupling surface (122C2). The second coupling surface (122C2) may be connected to the third coupling surface (122C3), and the third coupling surface (122C3) may be connected to the first lower surface (122D).

[0066] In an exemplary embodiment, the first cross beam (122) may include at least one first groove (122G) recessed into the inner side of the second engagement surface (122C2). The handle (123H) of the second cross beam (123) may be inserted into the first groove (122G) of the first cross beam (122).

[0067] Referring to FIGS. 2 and 3, the X-direction length of the first lower surface (122D) may be smaller than the X-direction length of the first upper surface (122U). The Y-direction length of the first lower surface (122D) may be substantially equal to the Y-direction length of the first upper surface (122U). In an exemplary embodiment, the second coupling surface (122C2) may be parallel to the upper surface (110BU) of the base plate (110B), and the first coupling surface (122C1) and the third coupling surface (122C3) may be perpendicular to the upper surface (110BU) of the base plate (110B).

[0068] In an exemplary embodiment, the first engagement surface (122C1) may be substantially perpendicular to the second engagement surface (122C2). The first engagement surface may extend in the Z direction from the second engagement surface (122C2). In an exemplary embodiment, the third engagement surface (122C3) may be substantially perpendicular to the second engagement surface (122C2). The third engagement surface (122C3) may extend in a direction opposite to the Z direction from the second engagement surface (122C2). In an exemplary embodiment, the first groove (122G) of the second engagement surface (122C2) may be formed in a direction away from the base plate (110B).

[0069] In an exemplary embodiment, the first cross beam (122) may include a plurality of first grooves (122G). The plurality of first grooves (122G) may be arranged at regular intervals in the Y direction. The plurality of first grooves (122G) may be arranged at regular intervals in a first direction parallel to the upper surface of the base plate (110B).

[0070] Referring to FIGS. 2 and 4, the second cross beam (123) may include a second upper surface (123U) and a second lower surface (123D). The second upper surface (123U) and the second lower surface (123D) may be substantially parallel to the base plate upper surface (110BU). The second lower surface (123D) may be in contact with the base plate (110B), and the first upper surface (122U) may be located on the opposite side of the first lower surface (122D). In an exemplary embodiment, the X-direction length of the second lower surface (123D) may be greater than the X-direction length of the second upper surface (123U). The Y-direction length of the second lower surface (123D) may be substantially the same as the Y-direction length of the first upper surface (123U).

[0071] The second cross beam (123) may have a second step structure (123C) including a fourth coupling surface (123C1), a fifth coupling surface (123C2), and a sixth coupling surface (123C3) that are sequentially connected. The second upper surface (123U) may be connected to the fourth coupling surface (123C1), and the fourth coupling surface (123C1) may be connected to the fifth coupling surface (123C2). The fifth coupling surface (123C2) may be connected to the sixth coupling surface (123C3), and the sixth coupling surface (123C3) may be connected to the first lower surface (123D).

[0072] In an exemplary embodiment, referring to FIGS. 2 and 4, the fifth engagement surface (123C2) may be parallel to the upper surface (110BU) of the base plate (110B), and the fourth engagement surface (123C1) and the sixth engagement surface (123C3) may be perpendicular to the upper surface (110BU) of the base plate (110B). In an exemplary embodiment, the fourth engagement surface (123C1) may be perpendicular to the fifth engagement surface (123C2) and may extend from the fifth engagement surface (123C2) in a direction away from the base plate (110B). In an exemplary embodiment, the sixth engagement surface (123C3) may be perpendicular to the fifth engagement surface (123C2), and may extend from the fifth engagement surface (123C2) in a direction toward the base plate (110B).

[0073] In an exemplary embodiment, the fifth engagement surface (123C2) may include at least one second groove (123G) recessed inwardly and a handle (123H) embedded in the second groove (123G). The second groove (123G) may be formed in a direction away from the fifth engagement surface (123C2).

[0074] In an exemplary embodiment, the handle (123H) may be configured to rotate. The rotation axis of the handle (123H) may be substantially parallel to the first direction, i.e., the Y direction. The rotation axis of the handle (123H) may be substantially perpendicular to the second direction, i.e., the X direction. The rotation axis of the handle (123H) may be embedded in the second groove (123G), and the handle (123H) may be partially embedded in the second groove (123G). The fully folded handle (123H) may be parallel to the fifth engaging surface (123G) and may be seated in the second groove (123G).

[0075] In an exemplary embodiment, the rotation axis of the handle (123H) may be substantially parallel to the fourth engagement surface (123C1). In an exemplary embodiment, the rotation axis of the handle (123H) may be substantially parallel to the Y-direction of the fourth engagement surface (123C1), i.e., the edge in the first direction. In an exemplary embodiment, the rotation axis of the handle (123H) may be substantially parallel to the sixth engagement surface (123C3). In an exemplary embodiment, the rotation axis of the handle (123H) may be substantially parallel to the Y-direction of the sixth engagement surface (123C3), i.e., the edge in the first direction.

[0076] In an exemplary embodiment, as illustrated in FIGS. 4 and 5 , the rotation axis of the handle (123H) may be closer to the fourth engagement surface (123C1) than to the sixth engagement surface (123C3). At this time, the unfolded handle (123H) may be substantially perpendicular to the fifth engagement surface (123G). The unfolded handle (123H) may rotate clockwise to be accommodated in the second groove (123G).

[0077] In an exemplary embodiment, the rotation axis of the handle (123H) may be closer to the sixth engagement surface (123C3) than to the fourth engagement surface (123C1). In this case, the unfolded handle (123H) may be substantially perpendicular to the fifth engagement surface (123G). The unfolded handle (123H) may be rotated counterclockwise to be accommodated in the second groove (123G).

[0078] Through rotation, the handle (123H) may be parallel to the first lower surface (123D) or perpendicular to the first lower surface (123D). In an exemplary embodiment, the handle (123H) may be parallel to the base plate (110B) or perpendicular to the base plate (110B).

[0079] In an exemplary embodiment, the handle (123H) is hinged to the second groove (123G), wherein the depth (d2) of the second groove (123G) may be equal to or greater than the thickness (t) of the handle (123H). Accordingly, when the handle (123H) is folded parallel to the first lower surface (123D), the handle (123H) can be stored in the second groove (123G), and the storability of the second cross beam (123) can be improved.

[0080] In an exemplary embodiment, the second cross beam (123) may include a plurality of second grooves (123G) and a plurality of handles (123H). In an exemplary embodiment, the fifth engagement surface (123C2) may include a plurality of second grooves (123G) and a plurality of handles (123H). The second grooves (123G) and the handles (123H) may be arranged at regular intervals in the Y direction. Each of the handles (123H) of the second cross beam (123) may be coupled with a corresponding one of the first grooves (122G) of the first cross beam (122). For example, each of the handles (123H) may be coupled with a Z-axis overlapping one of the first grooves (122G).

[0081]

[0082] Figure 6 is an enlarged partial cross-sectional view of part (B) of Figure 2.

[0083] Referring to FIGS. 2 and 6, the first cross beam (122) and the second cross beam (123) can overlap each other in the Z direction. The handle (123H) of the second cross beam (123) can be inserted into the first groove (122G) of the first cross beam (122). In an exemplary embodiment, the height (h) of the handle (123H) can be substantially equal to or smaller than the depth (d1) of the first groove (122G). The height (h) of the handle (123H) can mean the length in the Z direction from the fifth coupling surface (123C2). When the handle (123H) is inserted into the first groove (122G), the first cross beam (122) and the second cross beam (123) can be coupled. In this way, the first cross beam (122) may have a different shape from the second cross beam (123) and a complementary shape. Accordingly, the first cross beam (122) and the second cross beam (123) may be strongly coupled to each other without an element for fixing the first cross beam (122) and the second cross beam (123). Accordingly, the assembling efficiency of the battery pack (100) may be improved.

[0084] The first to third coupling surfaces (122C1 to 122C3) of the first cross beam (122) can be coupled with the fourth to sixth coupling surfaces (123C1 to 123C3) of the second cross beam (123). For example, the first coupling surface (122C1) can be in contact with the fourth coupling surface (123C1), the second coupling surface (122C2) can be in contact with the fifth coupling surface (123C2), and the third coupling surface (122C3) can be in contact with the sixth coupling surface (123C3).

[0085]

[0086] (Example 2)

[0087] FIG. 7 is a cross-sectional view showing a battery pack (101) according to exemplary embodiments.

[0088] Referring to FIG. 7, the battery pack (101) may include a lower frame (110') and a plurality of battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6). The lower frame (110') may include a base plate (110'B), a first side plate (110'S1) connected to a first side of the base plate (110'B), and a second side plate (110'S2) connected to a second side of the base plate (110'B). For example, the lower frame (110') may be formed integrally.

[0089] In an exemplary embodiment, the first side plate (110'S1) of the lower frame (110') may include a protruding structure (111) that may be inserted into a first groove (122G). The protruding structure (111) may extend in a second direction, i.e., the Y direction, which is parallel to the upper surface (110'BU) of the base plate. In an exemplary embodiment, a Z-direction length of the protruding structure (111) may be substantially the same as a Z-direction length of the first groove (122G). In an exemplary embodiment, an X-direction length of the protruding structure (111) may be substantially the same as an X-direction length of the first groove (122G). Accordingly, the protruding structure (111) of the first side plate (110'S1) may be inserted into the first groove (122G) of the first battery assembly (120_1) disposed on the base plate (110'B). Accordingly, the first battery assembly (120_1) can be easily installed on the lower frame (110'). In addition, since the protruding structure (111) can be confirmed when assembling the battery pack (100), visibility can be improved, and the assembling efficiency of the battery pack (101) can be improved.

[0090] In an exemplary embodiment, the protruding structure (111) may have substantially the same shape as the handle (123H). For example, the thickness of the protruding structure (111) may be substantially the same as the thickness of the handle (123H). In an exemplary embodiment, the Z-direction length of the protruding structure (111) may be substantially the same as the Z-direction length of the handle (123H).

[0091] In an exemplary embodiment, the first side plate (110'S1) of the lower frame (110') can be coupled with the first cross beam (122) of the first battery assembly (120_1), the second cross beam (123) of the first battery assembly (120_1) can be coupled with the first cross beam (122) of the second battery assembly (120_2), and the second cross beam (123) of the second battery assembly (120_2) can be coupled with the first cross beam (122) of the third battery assembly (120_3). That is, the lower frame (110'), the first battery assembly (120_1), the second battery assembly (120_2), and the third battery assembly (120_3) can be sequentially engaged. This makes it possible to easily fix the battery assemblies (120_1, 120_2, 120_3, 120_4, 120_5, 120_6) to the lower frame (110'), thereby improving the assembly of the battery pack (101).

[0092]

[0093] (Example 3)

[0094] FIG. 8 is a cross-sectional view showing a battery pack (102) according to exemplary embodiments.

[0095] Referring to FIG. 8, the battery pack (102) may include a lower frame (110'') and a plurality of battery assemblies (120_1, 120_2, 120_3', 120_4, 120_5, 120_6'). The lower frame (110'') may include a first side plate (110''S1) and a second side plate (110''S2), each of which may include a protruding structure (111).

[0096] In an exemplary embodiment, the third battery assembly (120_3') may include a first cross beam (122) coupled to a first side (121S1) of the cell stack (121) and a first cross beam coupled to a second side (121S2) of the cell stack (121). The second side plate (110''S2) of the lower frame (110'') may include a protruding structure (111) that may be inserted into the first groove (122G). Accordingly, the third battery assembly (120_3) may be coupled with the second battery assembly (120_2) and the second side plate (110''S2), thereby improving the coupling property of the battery pack (100).

[0097] Since the sixth battery assembly (120_6') has substantially the same structure as the third battery assembly (120_3'), duplicate details are omitted.

[0098] Since the protruding structure (111) of the second side plate (110''S2) has substantially the same shape as the protruding structure (111) of the first side plate (110''S2), the duplicated content is omitted.

[0099]

[0100] How to assemble a battery pack

[0101] FIG. 9 is a flowchart illustrating a battery pack assembly method according to exemplary embodiments.

[0102] FIG. 10 is a cross-sectional view of a first cross beam (122) and a second cross beam (123) according to exemplary embodiments. Specifically, FIG. 10 (a) is a cross-sectional view taken along the cutting line CC′ of the first cross beam (122) of FIG. 3, showing a ring-shaped wire (200) inserted therein, and FIG. 10 (b) is a cross-sectional view taken along the cutting line DD′ of the second cross beam (123) of FIG. 4, showing a ring-shaped wire (200) inserted therein.

[0103] Referring to FIGS. 9 and 10, a method for assembling a battery pack includes a step (P110) of providing first and second battery assemblies, each of which may include a cell stack and first and second cross beams coupled to the cell stack.

[0104] In an exemplary embodiment, a method for assembling a battery pack may include a step (P110) of assembling first and second battery assemblies, a step (P120) of placing a first battery assembly (120_1) on a base plate (110B) of a lower frame (110), and a step (P130) of placing a second battery assembly (120_2) on the base plate (110B), wherein a handle (122H) of a second cross beam (123) of the first battery assembly (120_1) is coupled to a first groove (122G) of a first cross beam (122) of the second battery assembly (120_2). The lower frame (110) may include a base plate (110B), a first side plate (110S1) connected to a first side of the base plate (110B), and a second side plate (110S2) connected to a second side of the base plate (110B). The first cross beam (122) may have a first step structure (122C) including a first coupling surface (122C1), a second coupling surface (122C2), and a third coupling surface (122C3) that are sequentially connected. The first cross beam (122) may include a first groove (122G) recessed into the inside of the second coupling surface (122C2).

[0105] In an exemplary embodiment, the step (P110) of assembling the first and second battery assemblies may include the steps of transporting the first cross beam (122) using the first groove (122G), transporting the second cross beam (123) using the handle (123H), and coupling the first cross beam (122) and the second cross beam (123) to the cell stack (121). For example, the first cross beam (122) may be transported by hanging a ring-shaped wire (200) on the first groove (122G). In an exemplary embodiment, referring to FIGS. 4, 5, and 10, the handle (123H) of the second cross beam (123) may rotate about a rotational axis (123R). The handle (123H) can be folded parallel to the fifth joining surface (123C1) and can also be unfolded perpendicular to the fifth joining surface (123C1). A ring-shaped wire (200) can be hung on the unfolded handle (123H) to transport the second cross beam (123). As a result, the mobility of the first cross beam (122) and the second cross beam (123) can be improved, thereby improving the assembly efficiency of the battery pack. The third battery assembly (120_3), the fourth battery assembly (120_4), the fifth battery assembly (120_5), and the sixth battery assembly (120_6) can also be assembled in the same manner.

[0106] The first side plate (110S1) may include a protruding structure (111) that can be coupled with the first groove (122G). The first battery assembly (120_1) may be placed on the base plate (110B) such that the protruding structure (111) of the first side plate (110S1) is inserted into the first groove (122G) of the first cross beam (122).

[0107] In an exemplary embodiment, in the step (P120) of placing the first battery assembly (120_1) on the base plate (110B) of the lower frame (110), the first battery assembly can be transported using the first groove (122G) of the first cross beam (122) and the handle (123H) of the second cross beam (123). For example, a ring-shaped wire (200) can be hung on each of the first groove (122G) and the handle (123H) of the first battery assembly (120_1), so that the first battery assembly (120_1) can be placed on the base plate (110B). The second battery assembly (120_2), the fourth battery assembly (120_4), and the fifth battery assembly (120_5) can also be transported in the same manner.

Claims

1. A lower frame including a base plate, a first side plate connected to a first side of the base plate, and a second side plate connected to a second side of the base plate; and comprising first and second battery assemblies arranged on the base plate; Each of the first and second battery assemblies includes a cell stack including a plurality of battery cells and a first cross beam coupled to a first side of the cell stack, The first cross beam has a first step structure including a first coupling surface, a second coupling surface, and a third coupling surface that are sequentially connected, and A battery pack, characterized in that the first cross beam includes a first groove recessed into the inner side of the second joining surface.

2. In paragraph 1, The second bonding surface is parallel to the upper surface of the base plate, The first bonding surface is perpendicular to the second bonding surface, and A battery pack, characterized in that the third bonding surface is perpendicular to the second bonding surface.

3. In paragraph 1, The first side plate includes a protruding structure inserted into the first groove, A battery pack, characterized in that the protruding structure extends in a first direction parallel to the upper surface of the base plate.

4. In paragraph 1, Each of the first and second battery assemblies further comprises a second cross beam coupled to the second side of the cell stack, The second side is opposite to the first side, The second cross beam has a second step structure including a fourth coupling surface, a fifth coupling surface, and a sixth coupling surface that are sequentially connected, The fifth engaging surface includes a second groove recessed inward and a handle partially embedded in the second groove, and A battery pack characterized in that the handle is configured to rotate.

5. In paragraph 4, The fifth bonding surface is parallel to the upper surface of the base plate, The fourth bonding surface is perpendicular to the fifth bonding surface, and A battery pack, characterized in that the sixth bonding surface is perpendicular to the fifth bonding surface.

6. In paragraph 5, A battery pack characterized in that the rotation axis of the handle is parallel to the fourth coupling surface.

7. In paragraph 4, A battery pack, characterized in that the fifth joining surface of the second cross beam of the first battery assembly is in contact with the second joining surface of the first cross beam of the second battery assembly.

8. In paragraph 4, The fourth joining surface of the second cross beam of the first battery assembly is in contact with the first joining surface of the first cross beam of the second battery assembly, and A battery pack, characterized in that the sixth joining surface of the second cross beam of the first battery assembly is in contact with the third joining surface of the first cross beam of the second battery assembly.

9. In paragraph 4, A battery pack, characterized in that the height of the handle of the second cross beam is equal to or smaller than the depth of the first groove of the first cross beam.

10. In paragraph 4, The above handle is hinged to the second groove, A battery pack characterized in that the depth of the second groove is equal to or greater than the thickness of the handle.

11. A lower frame including a base plate; and comprising first and second battery assemblies arranged on the base plate; Each of the first and second battery assemblies includes a cell stack including a plurality of battery cells, a first cross beam coupled to a first side of the cell stack, and a second cross beam coupled to a second side of the cell stack, The second side is opposite to the first side, The first cross beam includes a plurality of first grooves recessed inwardly, and The second cross beam includes a plurality of second grooves and a plurality of handles recessed inwardly, A battery pack, wherein each of the plurality of handles is partially embedded in a corresponding one of the plurality of second grooves.

12. In paragraph 11, Each of the plurality of handles of the second cross beam is coupled with a corresponding one of the plurality of first grooves of the first cross beam, The above handle is configured to be rotatable by a rotation axis, and A battery pack, characterized in that the rotation axis is parallel to the first direction, which is parallel to the upper surface of the base plate.

13. A step of providing first and second battery assemblies, each of the first and second battery assemblies including a cell stack and first and second cross beams coupled to the cell stack, A step of placing the first battery assembly on the base plate of the lower frame; and A step of placing the second battery assembly on the base plate, wherein the handle of the second cross beam of the first battery assembly and the first groove of the first cross beam of the second battery assembly are coupled, The lower frame includes a base plate, a first side plate connected to a first side of the base plate, a second side plate connected to a second side of the base plate, and A battery pack assembly method, characterized in that the first cross beam includes a first groove, and the second cross beam includes a second groove and a handle hinged to the second groove.

14. In paragraph 13, A battery pack assembly method characterized in that the first battery assembly is placed on the base plate using the first groove of the first cross beam and the handle of the second cross beam.

15. In paragraph 13, A battery pack assembly method, characterized in that the first battery assembly is placed on the base plate such that the protruding structure of the first side plate is inserted into the first groove of the first cross beam.

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