Battery pack and method of assembling the battery pack

• US 10,084,218 B2
• Filed: 05/09/2014
• Issued: 09/25/2018
• Est. Priority Date: 05/09/2014
• Status: Active Grant

• Current Assignee: LG Energy Solution Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: Merriman, Robert, Yang, Heekook
• Primary Examiner(s): Zeng, Lingwen R
• Application Number:
  US14/273,572
• Publication Number:
  US 20150325894A1
• Time in Patent Office: 1,600 Days
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/655 Solid structures for heat exchange or heat conduction
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6555 arranged between the cells
• CPC Class Codes: H01M 10/6556 Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 10/6557 arranged between the cells
• CPC Class Codes: H01M 10/6563 with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/6566 Means within the gas flow to guide the flow around one or more cells, e.g. manifolds, baffles or other barriers H01M10/6565 takes precedence
• CPC Class Codes: H01M 10/667 the system being an electronic component, e.g. a CPU, an inverter or a capacitor
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/276 Inorganic material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/4911 including sealing

Abstract

A battery pack having a battery pack housing defining an interior region is provided. The housing further includes an inlet aperture and an outlet aperture communicating with the interior region. The battery pack further includes a battery module that is disposed in the interior region of the battery pack housing proximate to the inlet aperture. The battery module has a first battery cell, a heat exchanger, and first and second end plates. The first battery cell and the heat exchanger are disposed against one another, and are further disposed between the first and second end plates. The heat exchanger defines a first flow path portion therethrough. The first end plate has a first end portion that extends longitudinally past the first end of the first battery cell, and a second end portion that extends longitudinally past the second end of the first battery cell.

Claims

1. A battery pack, comprising:

a battery pack housing having a base portion and an upper cover;

the base portion and the upper cover defining an interior region when the upper cover is coupled to the base portion, the base portion having a bottom wall and first and second side walls coupled to the bottom wall, the first side wall having an inlet aperture extending therethrough that communicates with the interior region, the second side wall having an outlet aperture extending therethrough that communicates with the interior region;

a battery module being disposed in the interior region of the battery pack housing proximate to the inlet aperture, the battery module having a first battery cell, a first frame member, and first and second end plates;

the first frame member having a first rectangular ring-shaped outer plastic frame and a first aluminum heat exchanger, the first rectangular ring-shaped outer plastic frame being coupled around an outer peripheral region of first and second thermally conductive plates of the first aluminum heat exchanger, the first rectangular ring-shaped outer plastic frame having first, second, third, and fourth walls;

the first and second walls extending parallel to one another;

the third and fourth walls extending parallel to one another and perpendicular to the first and second walls;

the first wall having first, second, and third apertures extending therethrough with the second aperture thereof being disposed between the first and third apertures thereof;

the second wall having first, second, and third apertures extending therethrough with the second aperture thereof being disposed between the first and third apertures thereof;

the first and second thermally conductive aluminum plates being coupled together and directly contacting one another such that the first and second thermally conductive aluminum plates define a first flow path portion therebetween, the first flow path portion fluidly communicating with the first, second, and third apertures of the first wall of the first rectangular ring-shaped outer plastic frame and with the first, second, and third apertures of the second wall of the rectangular ring-shaped outer plastic frame;

the first battery cell and the first aluminum heat exchanger being disposed against one another, and being further disposed between the first and second end plates;

the first battery cell having a first end and a second end;

the first end plate extending substantially parallel to a longitudinal axis of the battery module, the first end plate having a first end portion and a second end portion, the first end portion of the first end plate extending longitudinally past the first end of the first battery cell toward the inlet aperture, the first end portion of the first end plate contacting the first side wall of the base portion above the inlet aperture and a first distance below a top end of the first side wall;

the second end portion of the first end plate extending longitudinally past the second end of the first battery cell;

the second end plate extending substantially parallel to the longitudinal axis of the battery module, the second end plate having a first end portion and a second end portion, the first end portion of the second end plate extending longitudinally past the first end of the first battery cell toward the inlet aperture;

the second end portion of the second end plate extending longitudinally past the second end of the first battery cell, the first end portion of the second end plate contacting the first side wall of the base portion below the inlet aperture and a second distance above a bottom end of the first side wall;

the second end plate being disposed away from the first end plate, and the first end portion of the first end plate and the first end portion of the second end plate forming a channel for routing air from the inlet aperture into the first, second, and third apertures in the first wall of the first rectangular ring-shaped outer plastic frame, and into the first flow path portion of the first aluminum heat exchanger;

a thermally conductive housing being disposed in the interior region of the battery pack housing between the battery module and the outlet aperture of the battery pack housing;

the thermally conductive housing defining a second flow path portion between the thermally conductive housing and the battery pack housing, the second flow path portion communicating with the first flow path portion; and

an electric fan disposed in the interior region of the battery pack housing;

the electric fan adapted to urge the air to flow through the inlet aperture of the battery pack housing and through the first and second flow path portions and further through a portion of the electric fan and through the outlet aperture of the battery pack housing.

2. The battery pack of claim 1, wherein the thermally conductive housing having a bottom wall and a plurality of cooling fins extending outwardly from the bottom wall thereof and spaced apart from one another such that the second flow path portion is at least partially defined between the plurality of cooling fins.

3. The battery pack of claim 2, wherein the thermally conductive housing holds a DC/DC voltage converter that is electrically coupled to the first battery cell of the battery module.

4. The battery pack of claim 3, wherein the battery module being disposed on the bottom wall of the base portion, and the plurality of cooling fins of the thermally conductive housing being disposed on the bottom wall of the base portion.

5. The battery pack of claim 2, wherein the thermally conductive housing is constructed of aluminum.

6. The battery pack of claim 1, wherein the first battery cell is disposed against a first side of the first aluminum heat exchanger, the battery module further having a second battery cell disposed against the first side of the first aluminum heat exchanger.

7. The battery pack of claim 1, wherein the first flow path portion having at least first and second flow path subportions extending through the first and second thermally conductive plates.

8. The battery pack of claim 7, wherein the first battery cell being disposed against a first side of the first thermally conductive plate of the first aluminum heat exchanger, the battery pack further comprising a second battery cell being disposed against the first side of the first thermally conductive plate of the first aluminum heat exchanger.

9. The battery pack of claim 1, wherein the electric fan is further disposed proximate to the outlet aperture of the battery pack housing.

10. The battery pack of claim 1, wherein the base portion further includes third and fourth side walls;

the first, second, third and fourth side walls are coupled to the bottom wall and extend upwardly substantially perpendicular to the bottom wall, the first and second side walls extend substantially parallel to one another, the third and fourth side walls extend substantially parallel to one another and perpendicular to the first and second side walls.

11. The battery pack of claim 1, wherein the battery module further includes a second battery cell and a second frame member, the second frame member having a second aluminum heat exchanger;

the second battery cell being disposed against and between the second aluminum heat exchanger and the first battery cell;

the second battery cell and a second aluminum heat exchanger being further disposed between the first and second end plates;

the second aluminum heat exchanger defining a third flow path portion therethrough that extends substantially parallel to the first flow path portion.

12. The battery pack of claim 11, wherein the first and third flow path portions of the first and second aluminum heat exchangers, respectively, extend substantially parallel to the longitudinal axis of the battery module, such that the air flows substantially longitudinally through the first and second aluminum heat exchangers.

13. The battery pack of claim 11, wherein the first battery cell is a pouch-type lithium-ion battery cell having a substantially rectangular-shaped body that is disposed on and against the first aluminum heat exchanger, the second battery cell is a pouch-type lithium-ion battery cell having a substantially rectangular-shaped body that is disposed on and against the second aluminum heat exchanger.

17. The battery pack of claim 1, wherein a vertical length of the inlet aperture in the first side wall is greater than a combined vertical length of the first battery cell and the first aluminum heat exchanger.

19. The battery pack of claim 1, wherein:

the first thermally conductive plate having first and second elongated depressed portions disposed apart from another;

the second thermally conductive plate having first and second elongated depressed portions disposed apart from another; and

the first and second elongated depressed portions of the second thermally conductive plate being disposed directly against the first and second elongated depressed portions, respectively, of the first thermally conductive plate such that at least a portion of the first flow path portion is defined between the first and second elongated depressed portions of the first thermally conductive plate and between the first and second elongated depressed portions of the second thermally conductive plate.

14. A battery pack, comprising:

a battery pack housing having a base portion and an upper cover;

the base portion and the upper cover defining an interior region when the upper cover is coupled to the base portion, the base portion having a bottom wall and first and second side walls coupled to the bottom wall, the first side wall having an inlet aperture extending therethrough that communicates with the interior region, the second side wall having an outlet aperture extending therethrough that communicates with the interior region;

a battery module being disposed in the interior region of the battery pack housing proximate to the inlet aperture, the battery module having a first battery cell, a second battery cell, first and second frame members, and first and second end plates;

the first frame member having a first rectangular ring-shaped outer plastic frame and a first aluminum heat exchanger, the first rectangular ring-shaped outer plastic frame being coupled around an outer peripheral region of first and second thermally conductive plates of the first aluminum heat exchanger;

the first rectangular ring-shaped outer plastic frame having first, second, and third apertures extending through a first wall thereof with the second aperture being disposed between the first and third apertures;

the first rectangular ring-shaped outer plastic frame having fourth, fifth, and sixth apertures extending through a second wall thereof with the fifth aperture being disposed between the fourth and sixth apertures;

the first and second thermally conductive aluminum plates being coupled together and directly contacting one another such that the first and second thermally conductive aluminum plates define a first flow path portion therebetween;

the second frame member having a second rectangular ring-shaped outer plastic frame and a second aluminum heat exchanger, the second aluminum heat exchanger having first and second thermally conductive aluminum plates coupled together that define a second flow path portion therebetween;

the first battery cell and the first aluminum heat exchanger being disposed against one another, and being further disposed between the first and second end plates;

the first battery cell having a first end and a second end;

the second battery cell being disposed against and between the second aluminum heat exchanger and the first battery cell;

the second battery cell and a second aluminum heat exchanger being further disposed between the first and second end plates;

the second battery cell having a first end and a second end;

the first end plate extending substantially parallel to a longitudinal axis of the battery module, the first end plate having a first end portion and a second end portion, the first end portion of the first end plate extending longitudinally past both the first end of the first battery cell and the first end of the second battery cell toward the inlet aperture, the first end portion of the first end plate contacting the first side wall of the base portion above the inlet aperture and a first distance below a top end of the first side wall;

the second end portion of the first end plate extending longitudinally past both the second end of the first battery cell and the second end of the second battery cell;

the second end plate extending substantially parallel to the longitudinal axis of the battery module, the second end plate having a first end portion and a second end portion, the first end portion of the second end plate extending longitudinally past the first end of the first battery cell and the first end of the second battery cell toward the inlet aperture;

the second end portion of the second end plate extending longitudinally past the second end of the first battery cell and the second end of the second battery cell, the first end portion of the second end plate contacting the first side wall of the base portion below the inlet aperture and a second distance above a bottom end of the first side wall;

the second end plate being disposed away from the first end plate, and the first end portion of the first end plate and the first end portion of the second end plate forming a channel for routing the air from the inlet aperture into the first, second, and third apertures of the first wall of the first rectangular ring-shaped outer plastic frame and into the first flow path portion of the first aluminum heat exchanger, and routing the air from the inlet aperture into the second flow path portion of the second aluminum heat exchanger;

a thermally conductive housing being disposed in the interior region of the battery pack housing between the battery module and the outlet aperture of the battery pack housing;

the thermally conductive housing having a bottom wall and a plurality of cooling fins extending outwardly from the bottom wall and spaced apart from one another such that a third flow path portion is at least partially defined between the plurality of cooling fins, the third flow path portion communicating with the first and second flow path portions; and

an electric fan disposed in the interior region of the battery pack housing;

the electric fan adapted to urge the air to flow through the inlet aperture of the battery pack housing and through the first, second, and third flow path portions and further through a portion of the electric fan and through the outlet aperture of the battery pack housing.

15. The battery pack of claim 14, wherein the first and second flow path portions of the first and second aluminum heat exchangers, respectively, extend substantially parallel to the longitudinal axis of the battery module, such that the air flows substantially longitudinally through the first and second aluminum heat exchangers.

16. The battery pack of claim 14, wherein the first battery cell is a pouch-type lithium-ion battery cell having a substantially rectangular-shaped body that is disposed on and against the first aluminum heat exchanger, the second battery cell is a pouch-type lithium-ion battery cell having a substantially rectangular-shaped body that is disposed on and against the second aluminum heat exchanger.

18. The battery pack of claim 14, wherein a vertical length of the inlet aperture in the first side wall is greater than a combined vertical length of the first and second battery cells and the first and second aluminum heat exchangers.

20. The battery pack of claim 14, wherein:

the first thermally conductive plate having first and second elongated depressed portions disposed apart from another;

the second thermally conductive plate having first and second elongated depressed portions disposed apart from another; and

the first and second elongated depressed portions of the second thermally conductive plate being disposed directly against the first and second elongated depressed portions, respectively, of the first thermally conductive plate such that at least a portion of the first flow path portion is defined between the first and second elongated depressed portions of the first thermally conductive plate and between the first and second elongated depressed portions of the second thermally conductive plate.