Battery module and method of manufacturing supporter of the battery module

Abstract

An embodiment discloses a battery module comprising a case; a support disposed within the case and including a plurality of through holes; and a plurality of batteries each inserted into the plurality of through holes, wherein the support comprises a phase change material and a method for manufacturing the support of the battery module.

Description

Technology Field

[0001] The embodiment relates to a battery module and a method for manufacturing a support for the battery module. Background Technology

[0002] Recently, rechargeable secondary batteries are being widely used as energy sources for wireless mobile devices. Furthermore, secondary batteries are attracting attention as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (Plug-In HEVs), which are being proposed as solutions to address air pollution caused by conventional gasoline and diesel vehicles that use fossil fuels.

[0003] While small mobile devices use a relatively small number of battery cells per device, large and medium-sized devices such as automobiles use large and medium-sized battery modules in which multiple battery cells are electrically connected due to the need for high output and large capacity.

[0004] Since it is desirable for medium-to-large battery modules to be manufactured with the smallest possible size and weight, prismatic and pouch-type batteries, which can be produced with high integration density and have a low weight-to-capacity ratio, are primarily used as battery cells for medium-to-large battery modules.

[0005] Generally, when battery cells are used for a long time or during the charging and discharging process, a large amount of heat is generated, causing the internal temperature to rise rapidly. This rapid rise in internal temperature not only shortens the lifespan of the battery cell but also reduces the efficiency of the battery. Therefore, various battery cooling technologies are being developed to solve the aforementioned problems.

[0006] In battery usage, temperature management is a factor that significantly affects performance and safety. Air cooling and liquid cooling are the most commonly used methods for battery cooling.

[0007] However, since air-cooled systems have a structure where external air (or liquid) flows into the battery, they are relatively vulnerable to water damage and pose problems that compromise battery safety, such as condensation inside the case and humidity ingress.

[0008] Water-cooled systems pose a fire risk because the battery insulation becomes compromised if the cooling liquid leaks. Additionally, since external devices (such as chillers) are required for water cooling, there is a problem in that the water-cooled structure cannot be used in environments where such devices cannot be provided. The problem to be solved

[0009] The embodiment provides a battery module capable of cooling a battery using a phase change material.

[0010] The problem to be solved in the embodiments is not limited thereto, and may also include objectives or effects that can be identified from the means of solving the problem or the forms of implementation described below. means of solving the problem

[0011] A battery module according to one feature of the present invention comprises: a case; a support disposed within the case and including a plurality of through holes; and a plurality of batteries each inserted into the plurality of through holes, wherein the support comprises a phase change material.

[0012] The above support further comprises resin, and the phase change material may be included in an amount of 200 to 450 parts by weight per 100 parts by weight of the resin.

[0013] The above support includes a plurality of first through holes formed at the edge and a plurality of second through holes disposed inside the plurality of first through holes, and the plurality of batteries include a first battery disposed in the plurality of first through holes and a second battery disposed in the plurality of second through holes, and the first battery may have a portion of its side surface in contact with the case.

[0014] The above support may include a first protrusion that protrudes between the plurality of first batteries and contacts the inner surface of the case.

[0015] The above case may include a second protrusion that protrudes from the inner side and contacts the first protrusion.

[0016] The height of the above support may be 0.3 to 0.8 times the height of the plurality of batteries. Effects of the invention

[0017] According to the embodiment, a battery can be cooled using a phase change material. Therefore, the components required for cooling can be minimized, allowing the battery module to be manufactured in a smaller size. In addition, since the battery is maintained at an appropriate temperature by the phase change material, battery performance can be improved.

[0018] The various and beneficial advantages and effects of the present invention are not limited to those described above and may be more easily understood in the process of explaining specific embodiments of the present invention. Brief explanation of the drawing

[0019] FIG. 1 is an exploded perspective view of a battery module according to one embodiment of the present invention, and FIG. 2 is a drawing showing a state in which a plurality of batteries are inserted and fixed to a support, and FIG. 3 is a drawing showing a state in which multiple batteries are aligned by supports within a case, and Figure 4 is a graph of the temperature change of a phase change material, and Figure 5a is a graph showing the temperature change of a battery module with a support made of a phase change material and a conventional battery module. Figure 5b is a graph measuring the temperature difference between a battery module with a support made of a phase change material and a conventional battery module, and FIG. 6 is a drawing showing a first pressure plate and a second pressure plate for manufacturing a support, and FIG. 7 is a drawing showing the state of injecting molding resin between the first pressure plate and the second pressure plate, and Figure 8 is a drawing showing the state of a support made by injecting molding resin between the first pressure plate and the second pressure plate. Specific details for implementing the invention

[0020] The present invention is capable of various modifications and may have various embodiments, and specific embodiments are illustrated and described in the drawings. However, this is not intended to limit the invention to specific embodiments, and it should be understood that the invention includes all modifications, equivalents, and substitutions that fall within the spirit and scope of the invention.

[0021] Terms including ordinal numbers, such as second, first, etc., may be used to describe various components, but said components are not limited by said terms. Such terms are used solely for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, the second component may be named the first component, and similarly, the first component may be named the second component. The term "and / or" includes a combination of a plurality of related described items or any of a plurality of related described items.

[0022] When it is stated that one component is "connected" or "connected" to another component, it should be understood that while it may be directly connected or connected to that other component, there may also be other components in between. On the other hand, when it is stated that one component is "directly connected" or "directly connected" to another component, it should be understood that there are no other components in between.

[0023] The terms used in this application are used merely to describe specific embodiments and are not intended to limit the invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, terms such as "comprising" or "having" are intended to specify the presence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0024] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as generally understood by those skilled in the art to which the present invention pertains. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an ideal or overly formal sense unless explicitly defined in this application.

[0025] Hereinafter, embodiments will be described in detail with reference to the attached drawings, provided that identical or corresponding components are given the same reference number regardless of the drawing symbols, and redundant descriptions thereof will be omitted.

[0026] FIG. 1 is an exploded perspective view of a battery module according to one embodiment of the present invention, FIG. 2 is a drawing showing a state in which a plurality of batteries are inserted and fixed to a support, FIG. 3 is a drawing showing a state in which a plurality of batteries are aligned by a support within a case, and FIG. 4 is a graph of the temperature change of a phase change material.

[0027] Referring to FIGS. 1 and 2, a battery module according to an embodiment may include a case (110), a support (130) disposed within the case (110) and having a plurality of through holes (131, 132), and a plurality of batteries (120) each inserted into the plurality of through holes (131, 132).

[0028] The case (110) includes a first side and a second side facing each other, and a third side and a fourth side facing each other, and an insertion groove (111) into which a plurality of batteries (120) are inserted may be formed on the bottom surface. A circuit pattern (not shown) capable of connecting a plurality of batteries (120) in series and / or parallel may be formed on the inside of the insertion groove (111).

[0029] The case (110) may include a first case (110A) into which a battery (120) is inserted at the top and a second case (110B) into which a battery (120) is inserted at the bottom. According to an embodiment, the batteries (120) inserted in the first case (110A) and the batteries (120) inserted in the second case (110B) may be electrically connected to form a single battery module.

[0030] A cylindrical battery (120) may include a cylindrical housing (not shown) and an electrode assembly (not shown) housed inside the housing. Here, the electrode assembly may include a positive electrode coated with an electrode active material, a negative electrode, and a separator interposed between the positive electrode and the negative electrode.

[0031] The cylindrical battery (120) may be configured such that the housing is positioned vertically. The housing may be made of a material with high electrical conductivity, for example, aluminum or copper. However, it is not necessarily limited to this, and the housing may be made of a material with high thermal conductivity.

[0032] Electrode terminals (not shown) may be formed on the upper and lower portions of the cylindrical battery (120), respectively. Specifically, a first electrode terminal may be formed on the upper surface of the cylindrical battery (120), and a second electrode terminal may be formed on the lower surface.

[0033] A single battery module may be equipped with 84 cylindrical batteries (120). Additionally, among the 84 cylindrical batteries (120), 42 cylindrical batteries (120) may have a positive terminal formed at the top and a negative terminal formed at the bottom. The remaining 42 cylindrical batteries (120) may have a negative terminal formed at the top and a positive terminal formed at the bottom. However, the electrical connection method of the multiple batteries (120) can be applied without limitation to various series and parallel connection methods. Additionally, the number of batteries may increase or decrease depending on the type of electronic device to which they are applied.

[0034] An insulating member may be applied to the side of the battery (120). That is, since the battery (120) is electrically connected to the electrodes of the electrode assembly inside, an insulating film (not shown) or an electrically insulating adhesive may be applied to the side of the battery (120) to prevent electrical leakage caused by unintended conductive objects coming into contact with the housing.

[0035] Additionally, the electrode assembly (not shown) may be formed in a jelly-roll shape with a separator interposed between the anode and the cathode. Furthermore, an anode tab may be attached to the anode (not shown) and connected to a first electrode terminal at the top of the housing. And, a cathode tab may be attached to the cathode (not shown) and connected to a second electrode terminal at the bottom of the housing.

[0036] The upper cover (140) is coupled to the upper surface and side of the first case (110A) to accommodate a plurality of batteries (120) within the first case (110A). A fastening groove (142a) to which a projection (114) of the first case (110A) is coupled may be formed on the upper surface (141) and side (142) of the upper cover (140), respectively.

[0037] At this time, a pad (150) may be formed on the lower part of the upper cover (140). This pad (150) may be an electrode pad electrically connected to a plurality of batteries (120) or an elastic pad that protects the batteries (120) when pressurized. The lower cover (160) is coupled to the upper surface and side of the second case (110B) to accommodate a plurality of batteries within the second case (110B).

[0038] The support member (130) may include a plurality of first through holes (132) formed at the edge and a plurality of second through holes (131) disposed inside the plurality of first through holes (132). The plurality of first through holes (132) may not have a completely cylindrical shape.

[0039] The height (L1) of the support (130) may be 0.3 to 0.8 times the height (L2) of the multiple batteries (120). If the height (L1) of the support (130) is less than 0.3 times the height (L2) of the battery (120), the contact surface between the support (130) and the battery (120) is reduced, so heat transfer may not be smooth, and if the height (L1) of the support (130) is greater than 0.8 times, the battery (120) may not be sufficiently inserted into the insertion groove (111) of the case (110), so reliability issues may occur.

[0040] A plurality of batteries (120) may include a first battery (121) disposed in a plurality of first through holes (132) and a second battery (122) disposed in a plurality of second through holes (131). The first battery (121) and the second battery (122) may be the same battery (120), but only the position where they are inserted into the through holes (131, 132) may differ.

[0041] Multiple second batteries (122) are inserted into multiple second through holes (131) and supported on the sides, while multiple first batteries (121) have some sides exposed and can come into contact with the case (110).

[0042] Referring to FIG. 3, the support member (130) includes a first protrusion (133) that protrudes between a plurality of first batteries (121) and contacts the inner surface of the case (110), and the case (110) may include a second protrusion (113) that protrudes from the inner surface and contacts the first protrusion (133). Accordingly, heat generated from the batteries (120) can be transferred to the case (110) through the support member (130), and heat from the case (110) can be transferred to the batteries (120) through the support member (130). Additionally, a plurality of first batteries (121) can be safely supported within the case by the first protrusion (133) and the second protrusion (113).

[0043] The support (130) can be made of a phase change material. Therefore, not only can the rapid temperature change of the battery (120) due to the operation of the device be effectively suppressed, but the battery (120) can also be controlled to an optimal operating temperature range under harsh conditions, thereby improving the lifespan and safety of the battery (120).

[0044] The battery (120) generally has high heat generation during charging and low heat generation during discharging. Therefore, the support (130) can absorb heat from the battery (120) in a sealed space and then release the absorbed heat when the temperature of the battery (120) decreases, thereby maintaining the temperature of the battery (120).

[0045] Referring to FIG. 4, the optimal temperature of the battery (120) is 40°C to 45°C, and it can rise to about 58°C during charging. Accordingly, the support (130) according to the embodiment can be manufactured to undergo a phase change to absorb heat in the absorption temperature range of 40°C to 45°C and to release heat at temperatures below that.

[0046] The phase change material must undergo a phase change at a temperature at which the battery can exhibit optimal performance, and must also have a high latent heat during the phase change. Such phase change materials may include, for example, one or more selected from the group consisting of organic phase change materials, inorganic phase change materials, and paraffinic phase change materials.

[0047] The organic phase change material may be, for example, one or more selected from the group consisting of alkanes having 11 to 50 carbon atoms, pentaerythritol, polyethylene, acetamide, propylamide, naphthalene, stearic acid, polyglycol, wax, 3-heptadecanone, cyanamide, d-lactic acid, glycerol, acetic acid, and ethylenediamine.

[0048] Inorganic phase change materials are, for example, MgCl2·6H2O, Al2(SO4)3·10H2O, NH4Al(SO4)2·12H2O, KAl(SO4)2·12H2O, Mg(SO3)2·6H2O, SrBr2·6H2O, Sr(OH)2·8H2O, Ba(OH)2·8H2O, Al(NO3)2·9H2O, Fe(NO3)2·6H2O, NaCH2S2O2·5H2O, Ni(NO3)2·6H2O, Na2S2O2·5H2O, ZnSO4·7H2O, CaBr2·6H2O, Zn(NO3)2·6H2O, Na2HPO4·12H2O, Na2CO3·10H2O, Na2SO4·10H2O, LiNO2·3H2O and It may be one or more selected from the group consisting of CaCl2·6H2O.

[0049] Paraffinic phase change materials are, for example, C 12 H 26 , C 14 H 30 , C 16 H 34 , C 18 H 38 , C 19 H 40 , C 20 H 42 , C 21 H 44 , C 22 H 46 , C 24 H 50 , C 26 H 54 , C 27 H 56 , C 28 H 58 and C 30 H 62 It may be one or more types selected from a group consisting of

[0050] However, when a support is made using 100% phase change material, there is a problem with poor molding. Therefore, in the examples, resin was mixed to increase moldability. Specifically, the phase change material may be included in an amount of 200 to 450 parts by weight based on 100 parts by weight of resin.

[0051] If the phase change material is less than 200 parts by weight, the content of the phase change material decreases, and the heat absorption effect may be reduced. Also, if the phase change material is greater than 450 parts by weight, the relative content of resin decreases, and moldability may decrease. Therefore, cracks may occur during the process of molding the support (130). For example, the support (130) may be manufactured by mixing 80 wt% of the phase change material and 20 wt% of the resin, but is not necessarily limited thereto.

[0052] The resin may be an elastomeric polymer including a thermoplastic polymer elastomer (TPE). The polymer may be selected from polyurethanes (including elastomeric polyurethanes, thermoplastic polyurethanes (TPU), and elastomeric TPU), polyesters, polyethers, polyamides, vinyl polymers (e.g., copolymers of vinyl alcohols, vinyl esters, ethylene, acrylates, methacrylates, styrene, etc.), polyacrylonitrile, polyphenylene ethers, polycarbonates, polyureas, polystyrenes, copolymers thereof (including polyester-polyurethanes, polyether-polyurethanes, polycarbonates-polyurethanes, polyether block polyamides (PEBA), and styrene block copolymers), and any combination thereof. The polymer may comprise one or more polymers selected from the group consisting of polyesters, polyethers, polyamides, polyurethanes, polyolefins, their respective copolymers, and combinations thereof.

[0053] When supports were fabricated using polypropylene, defects occurred such as cracking and breakage even from minor external impacts; however, it was confirmed that moldability was improved when fabricated by mixing a ductile thermoplastic elastomer with a phase change material.

[0054] Figure 5a is a graph showing the temperature change of a battery module with a support made of a phase change material and a conventional battery module, and Figure 5b is a graph showing the temperature difference of a battery module with a support made of a phase change material and a conventional battery module.

[0055] Referring to FIGS. 5a and 5b, it can be seen that when the support (130) is made of a phase change material, the temperature change is smaller compared to when the support (130) is not made of a phase change material. When the phase change material is not applied, the maximum temperature increases to 58°C, whereas in the example, the maximum temperature is 51.5°C, so the maximum temperature difference is about 7.5°C.

[0056] In this way, when the support (130) is made of a phase change material, the temperature change of the battery (120) can be minimized, and the battery module can be manufactured much more simply compared to a configuration in which the phase change material is charged in the space between the batteries (120). In addition, there is an advantage that if a defect occurs in some of the batteries, they can be easily replaced.

[0057] FIG. 6 is a drawing showing a first pressure plate and a second pressure plate for making a support, FIG. 7 is a drawing showing the state of injecting molding resin between the first pressure plate and the second pressure plate, and FIG. 8 is a drawing showing the state of making a support by injecting molding resin between the first pressure plate and the second pressure plate.

[0058] Referring to FIG. 6, a first pressure plate (220) having a plurality of first protrusions (213) formed thereon and a second pressure plate (210) having a receiving groove (212) that accommodates the plurality of first protrusions (213) can be pressed while spaced apart from each other. In this case, since the plurality of first protrusions (213) do not overlap in a vertical direction with the plurality of second protrusions (211), the plurality of first protrusions (213) can be inserted into the receiving groove (212).

[0059] Referring to FIG. 7, molding resin can be injected between the first pressure plate (220) and the second pressure plate (210). Thus, as the molding resin is filled into the receiving groove (212), a support shape can be formed.

[0060] As described above, the molding resin may be in a state where the phase change material and the resin are mixed. Since the resin is a thermoplastic resin, it can be molded into the shape of a support (130) by filling it between the first pressure plate (220) and the second pressure plate (210) while applying appropriate heat.

[0061] Referring to FIG. 8, the production of the support (130) can be completed by lowering the temperature of the molding resin and separating the first pressure plate (220) and the second pressure plate (210). With this configuration, the support (130) can be produced using a phase change material by a simple production method. Since the phase change material and the resin are mixed, the moldability is excellent, which has the advantage of easily producing a support (130) having multiple through holes (131, 132).

[0062] Although the invention has been described above with reference to embodiments, this is merely illustrative and does not limit the invention. Those skilled in the art will understand that various modifications and applications not exemplified above are possible within the scope of the essential characteristics of the embodiments. For example, each component specifically shown in the embodiments may be modified and implemented. Furthermore, differences related to such modifications and applications should be interpreted as being included within the scope of the invention as defined in the appended claims.

Claims

Claim 1 A battery module comprising: a case; a support disposed within the case and including a plurality of through holes; and a plurality of batteries each inserted into the plurality of through holes, wherein the support comprises a mixture of a phase change material and a resin, and the through holes include a plurality of first through holes formed at the edge of the support, the edge side having an open shape, and the plurality of batteries include a first battery disposed in the plurality of first through holes, and the support has a plurality of first protrusions protruding between the first batteries, and among the plurality of first protrusions, some are in contact with the inner surface of the case, and other parts are not in contact with the inner surface of the case. Claim 2 A battery module according to claim 1, wherein the phase change material is included in an amount of 200 to 450 parts by weight per 100 parts by weight of the resin. Claim 3 In claim 1, the support comprises a plurality of second through holes disposed inside the plurality of first through holes, the plurality of batteries comprises second batteries disposed in the plurality of second through holes, and the first battery is a battery module in which a portion of its side surface contacts the case. Claim 4 delete Claim 5 In claim 1, the battery module comprising a case that protrudes from an inner surface and contacts a first protrusion. Claim 6 A battery module according to claim 1, wherein the height of the support is 0.3 to 0.8 times the height of the plurality of batteries. Claim 7 delete Claim 8 delete Claim 9 delete

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