Battery module and battery pack including the same

Abstract

According to an embodiment of the present invention, the battery module includes: a first unit block assembly and a second unit block assembly, each including a battery cell stack and a busbar frame mounted on the front and rear surfaces of the battery cell stack; a module frame that accommodates the first unit block assembly and the second unit block assembly and is open in the front-rear direction; and a top plate that covers the upper side surface and the front and rear surfaces of the first unit block assembly and the upper side surface and the front and rear surfaces of the second unit block assembly, wherein the first unit block assembly and the second unit block assembly are spaced apart from each other in a direction in which the busbar frames mounted in the first unit block assembly and the second unit block assembly face each other, and the top plate is connected to the bottom of the module frame between the first unit block assembly and the second unit block assembly and along the front and rear sides of the entire first unit block assembly and the second unit block assembly.

Description

Technical Field

[0001] This disclosure relates to battery modules and battery packs including the battery modules, and more specifically, to battery modules having scalable structures and battery packs including the battery modules. Background Technology

[0002] Rechargeable batteries are gaining attention as an energy source for various products such as mobile devices and electric vehicles. They are a powerful alternative to existing products that use fossil fuels, and are considered an environmentally friendly energy source because they do not produce byproducts from energy use.

[0003] Recently, with the increasing demand for high-capacity secondary battery structures, including the use of secondary batteries as energy storage, the demand for multi-module battery packs is also growing. A multi-module structure is a collection of battery modules in which multiple secondary batteries are connected in series or parallel.

[0004] Meanwhile, when multiple battery modules are connected in series or parallel to construct a battery pack, it is common to construct a battery pack by building a battery module consisting of at least one battery module and then adding other components to the at least one battery module.

[0005] Such a battery module includes a battery module stack with multiple battery modules, a module frame for housing the battery module stack, and an insulating cover and end plate covering the two side surfaces of the battery module stack.

[0006] Traditionally, the busbar frame is mounted on the front and rear surfaces of the battery cell stack in a direction perpendicular to the stacking direction of the battery cell stack constituting the battery module. Additionally, an insulating cover is attached to the outer surface of the busbar frame to cut off the electrical connection between the battery cell stack and the busbar frame and the outside. Furthermore, end plates are mounted on the outer surface of the insulating cover to physically protect the battery cell stack and the electrical components connected to it. However, when the battery module is manufactured by providing the insulating cover and end plates separately in this manner, the structure of the battery module can become complex.

[0007] On the other hand, in the case of battery modules recently installed in electric vehicles, various types of battery module structures have been released to efficiently utilize the vehicle's interior space. As the number of cell blocks increases, the demand for scalable battery module structures capable of utilizing vehicle interior space is growing.

[0008] In this case, with a scalable battery module structure comprising at least two or more cell blocks, when using end plates and insulating covers of conventional structures, an insulating cover and end plate must be provided separately for each battery cell stack. Therefore, the weight of the battery module can increase, the manufacturing process may be prolonged, and the battery module structure itself may become more complex. Summary of the Invention

[0009] Technical issues

[0010] The purpose of this disclosure is to provide a battery module with a simplified and scalable battery module structure, and a battery pack including the battery module.

[0011] The purpose of this disclosure is not limited to the foregoing, and other purposes not described herein should be clearly understood by those skilled in the art from the following detailed description.

[0012] Technical solution

[0013] To achieve the above objectives, according to one embodiment of this disclosure, a battery module is provided, comprising: a first unit block assembly and a second unit block assembly, each including a battery cell stack and a busbar frame, the busbar frame being mounted on the front and rear surfaces of the battery cell stack; a module frame accommodating the first unit block assembly and the second unit block assembly and having an opening in the front-rear direction; and a top plate covering the upper and front and rear surfaces of the first unit block assembly and the second unit block assembly, wherein the first unit block assembly and the second unit block assembly are spaced apart from each other in a direction in which the busbar frames mounted on the first unit block assembly and the second unit block assembly face each other, and the top plate is connected to the bottom of the module frame between the first unit block assembly and the second unit block assembly and along the front and rear sides of the entire first unit block assembly and the second unit block assembly.

[0014] The battery module may also include an insulating film formed on the inner surface of the upper plate.

[0015] The first and second unit block assemblies can be arranged in a direction perpendicular to the stacking direction of the battery cell stack.

[0016] A cooling plate can be installed at the bottom of the module frame.

[0017] A thermally conductive resin layer may be formed between the first unit block assembly and the second unit block assembly and the bottom of the module frame. The thermally conductive resin layer may be formed on the front and rear lower ends of the first unit block assembly and the front and rear lower ends of the second unit block assembly, respectively.

[0018] A first connecting member can be provided between the first unit block assembly and the second unit block assembly. A second connecting member and a third connecting member can be provided in the front-back direction of the entire first unit block assembly and the second unit block assembly. The connecting member can connect the upper plate and the module frame.

[0019] The upper plate includes a middle bottom formed between the first unit block assembly and the second unit block assembly, and a front bottom and a rear bottom formed in the front-rear direction of the entire first unit block assembly and the second unit block assembly, and the middle bottom is spaced apart from the bottom of the module frame, and the first connecting member can be connected and coupled to the middle bottom and the bottom of the module frame.

[0020] The front bottom and rear bottom contact the bottom of the module frame and can be connected to each other through the second connecting member and the third connecting member.

[0021] The battery module may also include an insulating film formed on the inner surface of the upper plate, wherein the insulating film is spaced apart from the intermediate bottom between the first unit block assembly and the second unit block assembly, and is formed to contact the bottom of the module frame.

[0022] According to one embodiment of this disclosure, a battery pack including the above-described battery module is provided.

[0023] Technical effect

[0024] According to this disclosure, by eliminating the end plates and insulating cover structures traditionally used in scalable battery module structures, the battery module can be made lighter, assembly performance can be improved, the unit production cost of the battery module can be reduced, and the component management cost can be reduced by reducing the number of components.

[0025] The effects of this disclosure are not limited to those described above, and those skilled in the art will clearly understand from the description of the appended claims other additional effects not described above. Attached Figure Description

[0026] Figure 1 This is an exploded perspective view of a battery module according to an embodiment of the present disclosure;

[0027] Figure 2 It shows Figure 1 A 3D view of the battery module assembly status;

[0028] Figure 3 yes Figure 2 Top view;

[0029] Figure 4 This is a perspective view showing the upper plate according to an embodiment of the present disclosure;

[0030] Figure 5 yes Figure 2 The AA cross-sectional view is a cross-sectional view of a battery module according to an embodiment of the present disclosure; and

[0031] Figure 6 This is a diagram showing the structure of a conventional battery module, including an end plate, as a comparative example;

[0032] [List of Labels in the Attached Image]

[0033] 100: First unit block assembly; 110: Battery cell stack

[0034] 120: Busbar frame; 200: Second unit block component

[0035] 210: Battery cell stack 220: Busbar frame

[0036] 300: Module framework 310: Bottom of module framework

[0037] 320: Two side surfaces of the module frame; 400: Top plate.

[0038] 401: Middle bottom; 402: Front bottom

[0039] 403: Bottom of rear end; 410: First connecting component

[0040] 420: Second connecting member; 430: Third connecting member

[0041] 500: Insulating film; 600: Cooling plate

[0042] 700: Thermally conductive resin layer Detailed Implementation

[0043] It should be understood that exemplary embodiments described below are illustrated to aid in understanding this disclosure, and various modifications may be made to this disclosure to implement it in a manner different from the exemplary embodiments described herein. However, in the description of this disclosure, specific descriptions and illustrations of well-known functions or constituent elements are omitted when it is determined that particular descriptions and illustrations may unnecessarily obscure the subject matter of this disclosure. Additionally, the drawings are not illustrated on actual scale to aid in understanding this disclosure, and the dimensions of some portions of the constituent elements may be exaggerated.

[0044] As used herein, terms such as first, second, etc., may be used to describe various components, and these components are not limited by these terms. These terms are only used to distinguish one component from another.

[0045] Furthermore, the terminology used herein is for describing specific exemplary embodiments only and is not intended to limit the scope of this disclosure. Singular expressions include plural expressions unless they have a clear opposite meaning in the context. It should be understood that the terms “comprising,” “including,” and “having” as used herein are intended to specify the presence of the stated features, quantities, steps, constituent elements, or combinations thereof, but should be understood that they do not exclude the possibility of the presence or addition of one or more other features, quantities, steps, constituent elements, or combinations thereof.

[0046] Now, refer to Figures 1 to 5 A battery module according to an embodiment of the present disclosure is described.

[0047] Figure 1 This is an exploded perspective view of a battery module according to an embodiment of the present disclosure. Figure 2 It shows Figure 1 A 3D view of the battery module assembly status. Figure 3 It was observed from above. Figure 2 Top view. Figure 4 This is a perspective view of the upper plate according to an embodiment of the present disclosure. Figure 5 It shows Figure 2 Section AA is a cross-sectional view of a battery module according to an embodiment of the present disclosure.

[0048] Reference Figures 1 to 5 The battery module according to embodiments of the present disclosure includes: a first unit block assembly 100 and a second unit block assembly 200, the first unit block assembly 100 and the second unit block assembly 200 including a battery cell stack 110 and a busbar frame 120 mounted to the front and rear surfaces of the battery cell stack 110; a module frame 300 that accommodates the first unit block assembly 100 and the second unit block assembly 200 and is open in the front-rear direction; and a top plate 400 that covers the upper side surface and the front and rear surfaces of the first unit block assembly 100 and the upper side surface and the front and rear surfaces of the second unit block assembly 200. The module frame 300 may be U-shaped.

[0049] At this time, the first unit block assembly 100 and the second unit block assembly 200 are arranged separately from each other in a direction in which the busbar frame 120 mounted on the first unit block assembly 100 and the second unit block assembly 200 face each other, and the upper plate 400 is connected to the bottom of the module frame 300 between the first unit block assembly 100 and the second unit block assembly 200 and on the front and rear sides of the entire first unit block assembly 100 and the second unit block assembly 200.

[0050] The battery cell according to this embodiment is a secondary battery and can be configured as a pouch-type secondary battery. Multiple battery cells can be constructed, and these multiple battery cells can be stacked to be electrically connected to each other, thereby forming a battery cell stack 110. Each of the multiple battery cells may each include an electrode assembly, a battery casing, and electrode leads protruding from the electrode assembly.

[0051] According to embodiments of this disclosure, the embodiment can be formed as a large-area cell block, wherein the number of stacked battery cells is significantly increased compared to conventional cases. Compared to the conventional case where approximately 12 to 24 battery cells are stacked in a cell block, a large-area cell block can include approximately 32 to 48 battery cells stacked in a cell block to form a battery cell stack 110.

[0052] The module frame 300 can accommodate the first unit block assembly 100 and the second unit block assembly 200. The module frame 300 is formed by a bottom 310 and two side surface portions 320, and can cover the entire lower surface portion and two side surface portions of the first unit block assembly 100 and the second unit block assembly 200. More specifically, the first unit block assembly 100 and the second unit block assembly 200 are arranged separately from each other in a direction where the busbar frames face each other, and the module frame 300 can be sized to accommodate the first unit block assembly 100 and the second unit block assembly 200 and the space between them, thereby accommodating the first unit block assembly 100 and the second unit block assembly 200. In this case, the first unit block assembly 100 and the second unit block assembly 200 can be arranged along a direction perpendicular to the stacking direction of the battery cell stack 110.

[0053] According to this embodiment, the upper plate 400 may have a shape in which a plurality of protrusions and recesses are formed, so as to integrally cover the upper surface and front and rear surfaces of the first unit block assembly 100 and the upper surface and front and rear surfaces of the second unit block assembly 200. The upper plate 400 may be formed to cover all parts where the busbar frame 120 is located, and may also be formed to cover the upper surface portions of the first unit block assembly 100 and the second unit block assembly 200.

[0054] Figure 6 This diagram illustrates the structure of a conventional battery module, including an end plate, as a comparative example.

[0055] A conventional battery module includes a battery cell stack 10 formed as a large area, a module frame 20 for accommodating the battery cell stack 10, an upper plate 30 for covering the upper surface of the battery cell stack 10, an end plate 40 for covering the front and rear surfaces of the battery cell stack 10, and a heat sink 50 formed below the bottom surface of the module frame 20.

[0056] At this point, in addition to the module frame 20 for accommodating the battery cell stack 10, an upper plate 30 covering the upper surface and end plates 40 covering the front and rear surfaces are provided to form the frame structure of the battery cell stack 10. However, in the case of the end plate 40 structure, it includes auxiliary structures that require a certain level of strength. For example, it is formed to cover the entire size of one side surface of the battery cell stack 10, which is formed as a large area, and a module mounting portion 41 for mounting onto the battery pack is formed on one side, such as... Figure 6 As shown. Therefore, the end plate 40 can account for a large portion of the total weight of the battery module. In addition, since the upper plate 30 and the end plate 40 must be installed separately in addition to the module frame 20, there is a problem of complex assembly process.

[0057] Furthermore, in the case of a scalable battery module structure with two battery blocks arranged as described in this disclosure, with Figure 6 Compared to a battery module consisting of individual unit blocks, the battery module becomes considerably heavier and its structure becomes relatively complex. Therefore, there is essentially a need for a compact structure that reduces the weight of the battery module and simplifies its design.

[0058] Therefore, according to this embodiment, the portions of the first unit block assembly 100 and the second unit block assembly 200 where the busbar frame 120 is provided can be covered by an integrally formed upper plate 400. Thus, the end plates provided in conventional battery modules can be eliminated, and both the upper and front / rear surfaces of the two unit block assemblies can be covered by a single upper plate 400, thereby reducing the weight occupied by conventional end plates and simplifying the structure of scalable large-area battery modules.

[0059] According to this embodiment, the insulating film 500 can be formed on the inner surface of the upper plate 400, such as... Figure 5 As shown. Traditionally, an insulating cover is additionally provided between the end plate and the busbar frame, requiring a separate process for assembling the insulating cover between the busbar frame and the end plate. However, according to this embodiment, the insulating film 500 is attached to the inner surface of the upper plate 400. Therefore, when assembling the upper plate 400, the insulating film 500 can also be simultaneously installed on the battery module, ensuring the insulation of the battery module through a simple assembly process.

[0060] According to this embodiment, a thermally conductive resin layer 700 may be formed between the first unit block assembly 100 and the second unit block assembly 200 and the bottom 310 of the module frame 300. The thermally conductive resin layer 700 may be formed on the lower ends of the front and rear sides of the first unit block assembly 100 and the lower ends of the front and rear sides of the second unit block assembly 200, respectively. The thermally conductive resin layer 700 may perform the function of transferring heat generated from the first unit block assembly 100 and the second unit block assembly 200 to the outside. The thermally conductive resin layer may include thermally conductive resin.

[0061] According to this embodiment, the cooling plate 600 can be disposed below the bottom 310 of the module frame 300. The battery module can be cooled by refrigerant flowing inside the cooling plate 600. A refrigerant flow path can be formed between the cooling plate 600 and the bottom 310 of the module frame 300. Therefore, unlike conventional cooling structures that provide a separate heat sink, a structure is adopted in which the refrigerant flow makes the bottom 310 of the module frame 300 part of the refrigerant flow path, thereby improving the cooling performance of the battery module and enabling the battery module to be lightweight.

[0062] The upper plate 400 can be connected to the bottom 310 of the module frame 300. More specifically, the first connecting member 410 is disposed between the first unit block assembly 100 and the second unit block assembly 200, the second connecting member 420 and the third connecting member 430 are disposed on the front and rear sides of the entire first unit block assembly 100 and the second unit block assembly 200, and the connecting members 410, 420 and 430 can connect the upper plate 400 and the module frame 300.

[0063] A close examination of the connection structure between the upper plate 400 and the module frame 300 reveals that the upper plate 400 includes an intermediate bottom 401 formed between the first unit block assembly 100 and the second unit block assembly 200, as well as a front bottom 402 and a rear bottom formed in the front and rear bottoms of the entire first unit block assembly 100 and the second unit block assembly 200. At this time, referring to... Figure 5 The middle bottom 401 is spaced apart from the bottom 310 of the module frame 300, and the first connecting member 410 is able to connect and link the bottom 401 between the bottom 401 and the bottom 310 of the module frame 300.

[0064] The insulating film 500 can extend downward from the intermediate bottom 401 between the first unit block assembly 100 and the second unit block assembly 200, and can be formed to contact the bottom 310 of the module frame 300. The front bottom 402 and the rear bottom 403 contact the bottom 310 of the module frame 300 and can be connected to each other by the second connecting member 420 and the third connecting member 430.

[0065] The bottom portion, capable of connecting to the module frame 300, is formed at both ends and the middle portion of the upper plate 400, and the portion where the bottom and the bottom of the module frame 300 intersect is connected by a connecting member, thereby enabling a secure connection between the upper plate 400 and the module frame 300. Simultaneously, it provides physical protection for the two unit block assemblies located between the upper plate 400 and the module frame 300.

[0066] The battery modules described above can be included in a battery pack, and these battery modules can be included in a battery pack. The battery pack can have a structure in which one or more battery modules according to embodiments of the present disclosure are aggregated together and encapsulated together with a battery management system (BMS) and a cooling device for controlling and managing the temperature, voltage, etc. of the battery.

[0067] Battery packs can be used in a variety of devices. Such devices can be used in vehicle devices such as electric bicycles, electric vehicles, or hybrid vehicles, but this disclosure is not limited thereto and is applicable to a variety of devices that can use battery modules, which are also within the scope of this disclosure.

[0068] While preferred embodiments of the present disclosure have been shown and described above, the scope of the disclosure is not limited thereto, and many other modifications can be made by those skilled in the art without departing from the spirit and scope of the invention as described in the appended claims. Furthermore, these modified embodiments should not be understood solely from the technical spirit or viewpoint of the present disclosure.

[0069] Cross-references to related applications

[0070] This application claims priority to Korean Patent Application No. 10-2020-0135446, filed with the Korean Intellectual Property Office on October 19, 2020, the disclosure of which is incorporated herein by reference in its entirety.

Claims

1. A battery module, the battery module comprising: A first unit block assembly and a second unit block assembly, the first unit block assembly and the second unit block assembly including a battery cell stack and a busbar frame, the busbar frame being mounted on the front and rear surfaces of the battery cell stack; A modular frame that accommodates the first unit block component and the second unit block component and has an opening in the front-back direction; The upper plate covers the upper surface and front and rear surfaces of the first unit block assembly and the upper surface and front and rear surfaces of the second unit block assembly; as well as An insulating film is formed on the inner surface of the upper plate. The first unit block assembly and the second unit block assembly are arranged spaced apart from each other in a direction in which the busbar frames mounted on the first unit block assembly and the second unit block assembly face each other. The upper plate is connected to the bottom of the module frame between the first unit block assembly and the second unit block assembly, and along the front and rear sides of the entire first unit block assembly and the second unit block assembly. The upper plate includes a middle bottom, a front bottom, and a rear bottom. The middle bottom is formed between the first unit block assembly and the second unit block assembly. The front bottom and the rear bottom are formed in the front-rear direction of the entire first unit block assembly and the second unit block assembly. The insulating film is spaced apart from the intermediate bottom between the first unit block assembly and the second unit block assembly, and is formed to contact the bottom of the module frame.

2. The battery module according to claim 1, in, The first unit block assembly and the second unit block assembly are arranged in a direction perpendicular to the stacking direction of the battery cell stack.

3. The battery module according to claim 1, in, A cooling plate is provided below the bottom of the module frame.

4. The battery module according to claim 3, in, A refrigerant flow path is formed between the cooling plate and the bottom of the module frame.

5. The battery module according to claim 1, in, A thermally conductive resin layer is formed between the first unit block assembly and the bottom of the module frame, and between the second unit block assembly and the bottom of the module frame, and the thermally conductive resin layer is formed on the front and rear lower ends of the first unit block assembly and the front and rear lower ends of the second unit block assembly, respectively.

6. The battery module according to claim 1, in, A first connecting member is provided between the first unit block assembly and the second unit block assembly, and a second connecting member and a third connecting member are provided in the front-rear direction of the entire first unit block assembly and the second unit block assembly, and the first connecting member, the second connecting member and the third connecting member connect the upper plate and the module frame.

7. The battery module according to claim 6, in, The intermediate bottom extends downward from the bottom of the module frame, and the first connecting member connects and links the intermediate bottom and the bottom of the module frame.

8. The battery module according to claim 7, in, The front bottom and the rear bottom contact the bottom of the module frame and are connected to each other by the second connecting member and the third connecting member.

9. The battery module according to claim 1, in, The upper plate has a shape forming multiple protrusions and recesses to integrally cover the upper and front and rear surfaces of the first unit block assembly and the upper and front and rear surfaces of the second unit block assembly.

10. A battery pack comprising a battery module according to any one of claims 1 to 9.

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