US-20260128435-A1 - PACK HOUSING AND MANUFACTURING METHOD OF BATTERY PACK

US20260128435A1US 20260128435 A1US20260128435 A1US 20260128435A1US-20260128435-A1

Abstract

A pack housing includes a base plate, a side member that forms a receiving space together with the base plate and that is connected with the base plate, and a cross member that extends in a direction crossing the side member. The side member includes an inner sidewall that faces the receiving space and a guide holder that protrudes toward the receiving space from the inner sidewall and forms a guide hole into which the cross member is inserted.

Inventors

Jong Gyu PARK
Kyung Mo Kim
Si Won Kim
Gun Woo Ko

Assignees

HYUNDAI MOTOR COMPANY
KIA CORPORATION

Dates

Publication Date: 20260507
Application Date: 20250623
Priority Date: 20241105

Claims (15)

1 . A pack housing comprising: a base plate; a side member configured to form a receiving space together with the base plate and connected with the base plate; and a cross member configured to extend in a direction crossing the side member, wherein the side member comprises: an inner sidewall configured to face the receiving space; and a guide holder configured to protrude toward the receiving space from the inner sidewall and form a guide hole into which the cross member is inserted.
2 . The pack housing of claim 1 , wherein the guide holder comprises a pair of holder walls configured to protrude toward the receiving space from the inner sidewall, the guide hole being located between the pair of holder walls.
3 . The pack housing of claim 2 , wherein each of the pair of holder walls extends in one direction perpendicular to the base plate, and wherein the guide hole extends in the one direction along the pair of holder walls.
4 . The pack housing of claim 3 , wherein the cross member is inserted into the guide hole in the one direction.
5 . The pack housing of claim 2 , wherein the guide holder further comprises: a connection wall configured to connect the pair of holder walls and brought into contact with the inner sidewall, the connection wall including an inner connection surface configured to face toward the guide hole; and an interference member brought into contact with the inner connection surface and configured to interfere with the cross member.
6 . The pack housing of claim 5 , wherein the interference member interferes with the cross member, allows the cross member to be inserted in one direction toward the guide hole, and prevents the cross member from being withdrawn from the guide hole in an opposite direction opposite to the one direction.
7 . The pack housing of claim 5 , wherein the interference member comprises: a support area brought into contact with the inner connection surface; and an interference protrusion area configured to protrude toward the guide hole from the support area and interfere with the cross member.
8 . The pack housing of claim 7 , wherein the interference protrusion area comprises: a protruding area connected to the support area and configured to protrude from the support area; and a cross member contact area configured to extend from the protruding area and spaced apart from the support area.
9 . The pack housing of claim 8 , wherein the protruding area has an inclined shape to form certain angles with one direction in which the cross member is inserted into the guide hole and a direction toward the cross member.
10 . The pack housing of claim 7 , wherein the cross member comprises: a guide surface disposed parallel to the support area and brought into contact with the interference protrusion area; and an interference surface configured to protrude toward the support area from the guide surface and interfere with one end of the interference protrusion area.
11 . The pack housing of claim 3 , wherein each of the pair of the holder walls comprises: an inner holder surface configured to face the guide hole; and an inlet holder surface configured to extend from the inner holder surface to have a certain angle with respect to an opposite direction opposite to the one direction, the inlet holder surface being formed such that a cross-sectional area of the guide hole on a plane perpendicular to the one direction is increased in the opposite direction.
12 . The pack housing of claim 3 , wherein the guide holder further comprises a connection wall configured to connect the pair of holder walls and brought into contact with the inner sidewall, and wherein the connection wall comprises: an inner connection surface configured to face the guide hole; and an inlet connection surface configured to extend from the inner connection surface to have a certain angle with respect to an opposite direction opposite to the one direction, the inlet connection surface being formed such that a cross-sectional area of the guide hole on a plane perpendicular to the one direction is increased in the opposite direction.
13 . A method for manufacturing a battery pack, the method comprising: preparing a base plate and a side member configured to form a receiving space together; mounting battery cell stacks in the receiving space; and inserting a cross member between the battery cell stacks after the cell mounting step, wherein the side member comprises: an inner sidewall configured to face the receiving space; and a guide holder configured to protrude toward the receiving space from the inner sidewall to form a guide hole, and wherein the inserting the cross member between the battery cell stacks comprises inserting the cross member into the guide hole.
14 . The method of claim 13 , wherein the guide hole extends in one direction perpendicular to the base plate, and wherein the inserting the cross member between the battery cell stacks further comprises inserting the cross member into the guide hole in the one direction.
15 . The method of claim 13 , wherein the guide holder comprises an interference member provided in the guide hole and configured to interfere with the cross member, and wherein the inserting the cross member between the battery cell stacks further comprises inserting the cross member into the guide hole until the cross member interferes with the interference member within the guide hole.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of priority to Korean Patent Application No. 10-2024-0155654, filed in the Korean Intellectual Property Office on Nov. 5, 2024, the entire contents of which are incorporated herein by reference in their entireties. TECHNICAL FIELD The present disclosure relates to a pack housing and a manufacturing method of a battery pack. BACKGROUND In recent years, there has been a marked emphasis on research and development for electric vehicles (EVs), which are recognized for their environmentally friendly characteristics, amidst the growing global concern over environmental degradation and the depletion of oil resources. This heightened urgency has spurred advancements in various categories related to electric vehicles, including plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), and fuel cell electric vehicles (FCEVs), among others. The shift towards EV technology holds promise for reducing greenhouse gas emissions, and also likely addresses the pressing need for sustainable alternatives to fossil fuel dependency. The design of EVs are at time designed with a battery pack housing that provides structural support for the individual battery cells, which serves as the primary power source for the vehicle's propulsion system. In tandem with this foundational component, ongoing research is being directed towards enhancing the capacity and energy density of these battery cells within the housing to improve the overall performance, range, and efficiency of EVs. To improve the capacity of battery cells, a cell-to-pack (CTP) configuration may be utilized in which the battery cells are directly integrated into the pack housing as a unified battery cell stack instead of being organized in discrete modules. This approach allows for increased energy density and improved thermal management, leading to a more efficient electrical performance. Furthermore, the integration of the battery cell stack within the pack housing may necessitate the incorporation of other structural elements, such as a cross member, which can have an important role in distributing the surface pressure exerted on the battery cell stack during operation. This structural support can be important for maintaining integrity and longevity of the battery system under various conditions. In view of the above, there is a significant demand for improved and simplified structural designs that facilitate the assembly of the cross member while ensuring its stability and effectiveness in supporting the battery cell stack. Such a design that minimizes the complexity can lead to reduced manufacturing costs and enhanced reliability of the battery system. Additionally, innovations aimed at optimizing the cross member's integration within the pack housing can result in improved overall performance, thus contributing to the advancement of battery technology. Such improved and simplified structural designs should identify efficient materials and designs that not only meet the structural requirements but also align with contemporary sustainability standards in battery manufacturing. SUMMARY The present disclosure has been made to solve the above-mentioned problems. In embodiments, the present disclosure provides a pack housing for easily assembling a cross member and stably supporting the cross member. The technical problems to be solved by the present disclosure are not limited to the aforementioned problems, and any other technical problems not mentioned herein will be clearly understood from the following description by those skilled in the art to which the present disclosure pertains. In embodiments, the present disclosure provides a pack housing comprises a base plate, a side member that forms a receiving space together with the base plate and that is connected with the base plate, and a cross member that extends in a direction crossing the side member. The side member comprises an inner sidewall that faces the receiving space and a guide holder that protrudes toward the receiving space from the inner sidewall and forms a guide hole into which the cross member is inserted. In embodiments, the guide holder comprises a pair of holder walls that protrude toward the receiving space from the inner sidewall, and the guide hole may be located between the pair of holder walls. Each of the pair of holder walls may extend in one direction perpendicular to the base plate, and the guide hole may extend in the one direction along the pair of holder walls. The cross member may be inserted into the guide hole in the one direction. In embodiments, the guide holder comprises a connection wall that connects the pair of holder walls and that is brought into contact with the inner sidewall, the connection wall including an inner connection surface that faces toward the guide hole and an interference member that is brought into contact with the inner connection surface and that interferes with the