EP-4736261-A1 - BATTERY PACK

EP4736261A1EP 4736261 A1EP4736261 A1EP 4736261A1EP-4736261-A1

Abstract

The battery pack (1) comprises at least one battery module (100) as an energy source of an electric power, and a protective casing (500) having a wall structure (502) that forms an inner space (510) for accommodating the at least one battery module (100). The battery pack (1) further comprises a support structure (10) remaining between the at least one battery module (100) and the inner space (510) of the protective casing (500), wherein the support structure comprises a main material (12) that is configured to expand and harden to form the support structure (10).

Inventors

TYYNELÄ, Santtu
PIEPPONEN, MIKKO

Assignees

Avant Tecno Oy

Dates

Publication Date: 20260506
Application Date: 20240627

Claims (1)

CLAIMS 1. A battery pack (1), wherein the battery pack (1) comprises at least one battery module (100) as an energy source of an electric power, wherein the at least one battery module (100) comprises a plurality of bat- tery cells (110), and a busbar assembly (120) configured to electrically couple the battery cells (110), and a housing (130) having an inner space (132) for accommo- dating at least the plurality of battery cells (110), a protective casing (500) having a wall structure (502) that forms an inner space (510) for accommodating the at least one battery module (100), wherein the wall structure (502) of the protective casing (500) is a double shell structure at least partially surrounding the inner space (510), and a support structure (10) remaining between the at least one battery module (100) and the wall structure (502) in the inner space (510) of the protec- tive casing (500), or the support structure (10) remaining inside the double shell structure of the protective casing (500), wherein the support structure (10) com- prises a main material (12) that is configured to expand and harden to form the support structure (10). 2. The battery pack (1) as claimed in claim 1, wherein the battery pack (1) comprises a heat transfer liquid (400-A) being arranged into the inner space (510), wherein the heat transfer liquid (400-A) at least partially surrounds the at least one battery module 100, and wherein the support structure (10) comprises at least one cover (14) into which the main material (12) is arranged for preventing contact between the heat trans- fer liquid (400-A) and the main material (12). 3. The battery pack (1) as claimed in claim 2, wherein the cover (14) comprises plastic material. 4. The battery pack (1) as claimed in claim 2 or 3, wherein the cover (14) has partition walls (15) for guiding the main material (12) to expand inside the cover (14). 5. The battery pack (1) as claimed in any one of claims 2–4, wherein the support structure (10) comprises a plurality of covers (14). 6. The battery pack (1) as claimed in in any one of the preceding claims, wherein the at least one battery module (100) has a top side (130A), a bottom side (130B) locating opposite relative to the top side (130A), and outer sides (130C) locating between the top side (130A) and the bottom side (130B), wherein the outer sides (130C) of the at least one battery module (100) are supported by the at least one support structure (10). 7. The battery pack (1) as claimed in in any one of the preceding claims, when the support structure (10) remains between the at least one battery module (100) and the wall structure (502) in the inner space (510) of the protective casing (500), the support structure (10) is extended against the at least one battery mod- ule (100) and the wall structure (502) in the inner space (510) of the protective casing (500). 8. The battery pack (1) as claimed in in any one of the preceding claims, wherein the main material (12) of the support structure (10) comprises polyure- thane, polyisocyanurate, synthetic rubber as nitrile, and/or synthetic polymers as silicone. 9. The battery pack (1) as claimed in in any one of the preceding claims, wherein the main material (12) of the support structure (10) is a polyurethane foam. 10. The battery pack (1) as claimed in in any one of the preceding claims, wherein the battery pack (1) comprises a power distribution unit (200) connected to the at least one battery module (100) for executing an electric connection, and a battery management system (300) connected to the power distribu- tion unit (200) for controlling the power distribution unit (200). 11. The battery pack (1) as claimed in in any one of the preceding claims, wherein the battery pack (1) comprises a heat transfer liquid (400-B) locating in the at least one battery module (100), which heat transfer liquid (400-B) balances heat between the heat transfer liquid (400-B) and the at least one battery module (100), an input (620) and an output (630) being arranged to the at least one battery module (100) allowing the heat transfer liquid (400-B) to flow through the at least one battery module (100), and a pump (600) for circulating the heat transfer liquid (400-B) through the at least one battery module (100). 12. The battery pack (1) as claimed in claim 11, wherein the battery pack (1) comprises a route (610) between the pump (600) and the at least one battery module (100), which route (610) guides the heat transfer liquid (400-B) from the pump (600) into the at least one battery module (100), and which route (610) guides the heat transfer liquid (400-B) from the at least one battery module (100) into the pump (600). 13. The battery pack (1) as claimed in any one of the preceding claims, wherein the battery pack (1) comprises a plurality of battery modules (100). 14. An electric vehicle comprising a battery pack (1) as claimed in any one of the preceding claims. 15. The electric vehicle as claimed in claim 14, wherein the electric ve- hicle is a mobile work machine. 16. An energy storage system comprising at least one battery pack (1) as claimed in any one of the claims 1–13. 17. A method for assembling a battery pack (1) as claimed in any one of the claims 1–14, wherein the method comprises inserting at least one battery module (100) into a protective casing (500), the protective casing (500) having a wall structure (502) that forms an inner space (510) for accommodating the at least one battery module (100), and inserting a main material (12) into the protective casing (500) after which the main material (12) expands and hardens to form a support structure (10) for the at least one battery module (100). 18. A method as claimed in claim 17, wherein the method comprises inserting at least one cover (14) into the protective casing (500), wherein the main material (12) is inserted into the cover (14) after which the main material (12) expands and hardens to form a support structure (10) for the at least one battery module (100), and inserting a heat transfer liquid (400-A) into the protective casing (500). 19. A method as claimed in claim 17 or 18, wherein the support struc- ture (10) remains between the at least one battery module (100) and the wall structure (502) in the inner space (510) of the protective casing (500). 20. A method as claimed in claim 17 or 18, wherein the wall structure (502) of the protective casing (500) is a double shell structure at least partially surrounding the inner space (510), and wherein the main material (12) remains inside the double shell structure of the protective casing (500). 21. A method as claimed in claim 20, wherein the main material (12) expands and therefore causes the wall structure (502) of the protective casing (500) to expand against the at least one battery module (100). 22. A method as claimed in claim 20 or 21, wherein the method com- prises inserting the protective casing (500) into an assembly mold (M) for partially preventing the protective casing (500) to bend.

Description

BATTERY^PACK FIELD OF THE INVENTION The invention relates to a field of battery packs. BACKGROUND OF THE INVENTION Different kind of battery packs are widely used in electric vehicles, for example. There is a plurality of modular battery modules available in the market that can be used to form a desired battery pack. A drawback with the battery packs of prior art is that the battery mod- ules of the battery pack get aimed to forces that break components of the battery module, for example. BRIEF DESCRIPTION OF THE INVENTION An object of the present invention is to provide a novel battery pack. The invention is characterized by the features of the independent claims. The invention is based on the idea of a battery pack, wherein the battery pack comprises at least one battery module as an energy source of an electric power, and a protective casing having a wall structure that forms an inner space for accommodating the at least one battery module. The battery pack further com- prises at least one support structure remaining between the at least one battery module and the inner space of the protective casing, wherein the support structure comprises a main material that is configured to expand and harden to form the support structure. An advantage of the solution is that forces aimed to the battery module are reduced effectively by the support structure. Some embodiments of the invention are disclosed in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS In the following the invention will be described in greater detail by means of preferred embodiments with reference to the attached drawings, in which Figure 1 shows schematically a battery pack as seen in a cross-sectional view as seen from a side of the battery pack, Figure 2 shows schematically a battery pack as seen in a cross-sectional view from above the battery pack, Figure 3A shows schematically and partially a battery module of Figure 1as seen in a cross-sectional view from a side of the battery module, Figure 3B shows schematically a detail of the battery module of Figure 3A as seen from above of the battery module, Figure 3C shows schematically a battery cell of the battery module of Figure 3A as seen obliquely from above the battery cell, Figure 4 shows schematically a section of a lower housing and the bat- tery cells of the battery module of the battery pack of Figure 1 as seen obliquely from above the battery module, Figure 5 shows schematically a section of a lower housing and the bat- tery cells of the battery module of the battery pack of Figure 1 as seen obliquely from above the battery module, Figure 6 shows schematically the battery pack of Figure 1 from above the battery pack, Figure 7 shows schematically a battery pack and an assembly mold as seen in a cross-sectional view as seen from a side of the battery pack, and Figure 8 shows schematically a battery pack of Figure 7 without the as- sembly mold. DETAILED DESCRIPTION OF THE INVENTION Figure 1 shows schematically a battery pack as seen in a cross-sectional view as seen from a side of the battery pack. Figure 2 shows schematically a battery pack as seen in a cross-sectional view from above the battery pack. Figure 3A shows schematically and partially a battery module of Figure 1as seen in a cross- sectional view from a side of the battery module. Figure 3B shows schematically a detail of the battery module of Figure 3A as seen from above of the battery module. Figure 3C shows schematically a battery cell of the battery module of Figure 3A as seen obliquely from above the battery cell. Figure 4 shows schematically a section of a lower housing and the battery cells of the battery module of Figure 1 as seen obliquely from above the battery module. Figure 5 shows schematically a section of a lower housing and the battery cells of the battery module of Figure 1 as seen obliquely from above the battery module. Figure 6 shows schematically the battery pack of Figure 1 from above the battery pack. Figure 7 shows schematically a bat- tery pack and an assembly mold as seen in a cross-sectional view as seen from a side of the battery pack. Figure 8 shows schematically a battery pack of Figure 7 without the assembly mold. The battery pack 1 of the Figures 1-6 comprises at least one battery module 100 as an energy source of an electric power. The battery pack 1 further comprises a protective casing 500 having a wall structure 502 that forms an inner space 510 for accommodating the at least one battery module 100. The battery pack 1 further comprises a support structure 10 remaining between the at least one battery module 100 and the inner space 510 of the protective casing 500, wherein the support structure comprises a main material 12 that is configured to expand and harden to form the support structure. The battery pack 1 of the Figures 7 and 8 comprises at least one battery module 100 as an energy source of an electric power. The battery pack 1 further comprises a protective casing 500 hav