Battery packs having structural members for improving thermal management

Abstract

Battery packs are presented having structural members for improving thermal management of battery cells therein. In some embodiments, the battery packs include a first end-member positioned opposite a second end-member and parallel thereto. The battery packs also include a first side beam positioned opposite a second side beam and parallel thereto. The first side beam and the second side beam extend longitudinally between the first end-member and the second end-member. A longitudinal member is disposed between the first side beam and the second side beam and defines a plurality of longitudinal rows. The battery packs may additionally include a lateral member disposed between first end-member and the second end-member to partition the plurality of longitudinal rows into an array of battery cell compartments. A battery cell is disposed within at least one battery cell compartment.

What is claimed is: 
     
         1 . A battery pack comprising:
 an enclosure having at least four sidewalls connected to a base;   a plurality of cells arranged in one or more rows and disposed on the base, with each cell of the plurality of cells having a large wall surface and a small wall surface, a surface area of the small wall surface being less that a surface area of the large wall surface; and   wherein, for each row of the one or more rows, each of the plurality of cells are arranged such their large wall surfaces are parallel to each other.   
     
     
         2 . The battery pack of  claim 1 , wherein two sidewalls of the at least four sidewalls are end plates that are arranged parallel to the large wall surfaces with one of the two sidewalls being adaptable to apply compressive force to the plurality of cells. 
     
     
         3 . The battery pack of  claim 1 , wherein the at least four sidewalls are mechanically attached or welded to the base. 
     
     
         4 . The battery pack of  claim 1 , wherein the battery pack is thermally coupled to a heat exchanger. 
     
     
         5 . The battery pack of  claim 1 , wherein at least 84 percent of a volume of the battery pack is occupied by cells. 
     
     
         6 . The battery pack of  claim 1 , wherein each row of the one or more rows has a same number of cells. 
     
     
         7 . The battery pack of  claim 1 , wherein the battery pack has at least two rows and each row is separated from an adjacent row by a divider. 
     
     
         8 . The battery pack of  claim 1 , wherein two other sidewalls of the at least four sidewalls are arranged opposite each other along a plane of the small wall surface to confine to the plurality of cells. 
     
     
         9 . A battery pack comprising:
 an enclosure having at least four sidewalls attached to a base;   wherein a first sidewall of the at least four sidewalls is arranged to apply a compressive load to a plurality of cells.   
     
     
         10 . The battery pack of  claim 9 , wherein the at least four sidewalls are welded to the base. 
     
     
         11 . The battery pack of  claim 9 , wherein the battery pack is thermally coupled to a heat exchanger. 
     
     
         12 . The battery pack of  claim 9 , wherein at least 84 percent of a volume of the battery pack is occupied by cells. 
     
     
         13 . The battery pack of  claim 9 , wherein the cells are arranged in a plurality of rows and each row of the plurality of rows has a same number of cells. 
     
     
         14 . The battery pack of  claim 9 , wherein the battery pack has at least two rows and each row is separated from an adjacent row by a divider. 
     
     
         15 . The battery pack of  claim 9 , wherein two other sidewalls of the at least four sidewalls are arranged opposite each to confine to the plurality of cells. 
     
     
         16 . A method for producing a battery pack, the method comprising:
 forming an enclosure that includes a base and at least four sidewalls, wherein at least one sidewall of the at least four sidewalls is mechanically attached to the base;   providing a plurality of cells each having a large wall surface and a small wall surface, wherein a surface area of the small wall surface is less than a surface area of the large wall surface;   arranging the plurality of cells on the base such that the large wall surfaces are parallel to each other; and   compressing the plurality of cells between at least two of the at least four sidewalls, the plurality of cells compressed in a direction perpendicular to the large wall surfaces.   
     
     
         17 . The method of  claim 16 , further comprising forming the enclosure and arranging the plurality of cells on the base of the enclosure such that at least 84% of a volume of the battery pack is occupied by the plurality of cells. 
     
     
         18 . The method of  claim 16 , wherein the at least four sidewalls are welded to the base. 
     
     
         19 . The method of  claim 16 , wherein the battery pack is thermally coupled to a heat exchanger. 
     
     
         20 . The method of  claim 16 , wherein at least 84 percent of a volume of the battery pack is occupied by cells.