Battery pack and method of manufacturing the same

Abstract

A battery pack including a foam kit assembly to uniformly fill an inside of a battery pack case with foam, and a method of manufacturing the battery pack, the battery pack including: a battery pack case in which an inside space is formed; a plurality of battery cells accommodated in the inside space of the battery pack case, arranged in a horizontal direction, and each formed to extend in a vertical direction; a foam kit assembly accommodated in the inside space of the battery pack case so as to be positioned above the plurality of battery cells, and isolated from the outside; and foam discharged from the foam kit assembly and filled between an inner surface of the battery pack case and the foam kit assembly.

Description

Technical Field

[0001] This disclosure relates to a battery pack including a foam kit assembly and a method of manufacturing the same, and more specifically, to a battery pack including a foam kit assembly capable of uniformly filling foam within a battery pack housing. Background Technology

[0002] As rechargeable batteries, secondary batteries are used in a variety of fields, from smartphones to electric vehicles. Depending on the type of device using the secondary battery, it may be used as a single battery cell or as a battery pack containing multiple battery cells. For example, secondary batteries used in small devices such as smartphones are used as a single battery cell. Conversely, secondary batteries used in medium and large devices such as electric vehicles are used as battery packs containing multiple battery cells.

[0003] When multiple battery cells form a battery pack for medium and large devices, a large number of battery cells are needed to meet the output voltage and charging capacity required in medium and large devices. The battery cells are packed into a small space filled with foam.

[0004] Foam performs many functions: blocking heat transfer between multiple battery cells, guiding material leaking from a ruptured battery cell away from another battery cell, and preventing short circuits between multiple battery cells.

[0005] Foam is injected into the battery pack housing through multiple ports defined in the sidewalls of the housing. Because the gaps between the multiple battery cells are narrow to increase the energy density of the battery pack, it is difficult to uniformly fill the foam between the narrowly arranged battery cells within the housing. Furthermore, since the foam used in battery packs typically has high viscosity, it is difficult to inject the foam deeply from the outside of the housing into the central portion of the housing, and even with deep injection, it is difficult to ensure uniform distribution of the foam along the height direction of the battery cells.

[0006] The background technology of this invention is disclosed in the following patent documents.

[0007] (Patent Document 1) KR10-2019-0097231 A

[0008] (Patent Document 2) KR10-0897899 B1 Summary of the Invention

[0009] Technical issues

[0010] This disclosure provides a battery pack and a method for manufacturing the same, the battery pack including a foam kit assembly capable of uniformly filling foam into the battery pack housing.

[0011] Technical solution

[0012] According to an exemplary embodiment, a battery pack includes: a battery pack housing having an internal space; a plurality of battery cells housed in the internal space of the battery pack housing, arranged horizontally and each extending vertically; a foam kit assembly housed in the internal space of the battery pack housing, such that the foam kit assembly is disposed on the plurality of battery cells and isolated from the outside; and foam discharged from the foam kit assembly and filling the space between the inner surface of the battery pack housing and the foam kit assembly. Here, the foam kit assembly includes: a support frame extending horizontally and having at least one opening allowing liquid foam to pass through vertically; a foam kit disposed on the support frame to contact and be pressed by a top cover of the battery pack housing, and having a receiving space formed therein for receiving liquid foam; and a pressing pin protruding from the support frame to penetrate the foam kit. Furthermore, the foam is formed such that liquid foam flows downward from the receiving space of the foam kit through a through-hole in the foam kit defined by the pressing pin, to form foam on the bottom surface of the outer shell of the battery pack housing.

[0013] The foam kit may have a top surface and a bottom surface, the top surface being in contact with and pressed down by the top cover, and the bottom surface being penetrated by the pressing pin.

[0014] The battery pack housing may include: an outer casing with an upward-facing interior opening; and a top cover that is attached to the upper opening of the outer casing to press down on the foam kit assembly.

[0015] The foam can solidify through the foaming and curing of liquid foam, and uniformly fill the gaps between multiple battery cells in the vertical direction while surrounding multiple battery cells.

[0016] The support frame can support the upper shape of the foam that is discharged from the through-holes of the foam kit and formed between multiple battery cells. Here, the support frame may include: an edge member that extends along the inner periphery of the upper opening of the housing; and a rod member disposed inside the edge member such that the foam kit is placed thereon and extends in the horizontal direction to be supported by the edge member, wherein at least one opening is formed in a grid shape.

[0017] The pressing needle can protrude upwards from multiple locations on the top surface of the rod member, the bottom surface of the foam kit can be penetrated by the pressing needle, and a gap can be formed between the penetrated portion of the foam kit and the outer peripheral surface of the pressing needle through which liquid foam flows downwards.

[0018] Multiple battery cells can be grouped based on their horizontal position, and multiple press pins can be configured such that the multiple press pins are aligned vertically with the center of each of the multiple groups and spaced apart from each other horizontally.

[0019] The foam kit may include: a bag-type ethylene cap; and at least one storage chamber formed in the bag-type ethylene cap to contain liquid foam, and the liquid foam may be a single-component liquid foam.

[0020] The foam kit may include: a bag-type vinyl cap; multiple storage chambers formed within the bag-type vinyl cap to contain liquid foam; and a separation membrane disposed within the bag-type vinyl cap to divide the interior of the bag-type vinyl cap into multiple storage chambers, and to rupture by pressure applied to the bag-type vinyl cap from the top cap. Here, the liquid foam may be a two-component liquid foam, and the base material and curing agent of the two-component liquid foam may be separately contained in the multiple storage chambers.

[0021] The bag-type vinyl cap can melt at the temperature of the heat generated during the foaming and curing of liquid foam.

[0022] According to another exemplary embodiment, a method of manufacturing a battery pack includes: a battery cell storage process: storing a plurality of battery cells arranged in a horizontal direction and each extending in a vertical direction in a housing with an internally upward opening; a foam kit assembly arrangement process: arranging a foam kit assembly containing liquid foam on the plurality of battery cells; a battery pack housing assembly process: assembling the battery pack housing by attaching a top cover to an upper opening of the housing; a liquid foam diffusion process: allowing a portion of the foam kit assembly to penetrate and diffuse liquid foam from the foam kit assembly into the entire internal space of the battery pack housing when the foam kit assembly contacts and is pressed by the top cover; and a foam formation process: forming foam between the inner surface of the battery pack housing and the foam kit assembly by foaming and curing the liquid foam.

[0023] The foam kit assembly arrangement process may include: a support frame arrangement process for placing the support frame of the foam kit assembly on a plurality of battery cells; a foam kit arrangement process for placing the foam kit of the foam kit assembly on the support frame; and a press pin contact process that allows the foam kit and the press pins of the foam kit assembly protruding from the support frame to contact each other.

[0024] The liquid foam diffusion process may include: a foam kit pressing process by pressing the foam kit downward through the top cover; a discharge hole forming process by forming a discharge hole by causing the pressing needle to penetrate the bottom surface of the foam kit; and a liquid foam discharge process by discharging the liquid foam contained in the foam kit onto multiple battery cells through the gap between the discharge hole and the outer peripheral surface of the pressing needle.

[0025] The liquid foam diffusion process may include: a liquid foam dispersion process that distributes liquid foam to multiple battery cells in a horizontal direction; and a liquid foam flow process that guides the liquid foam to flow downward from the top to the bottom of each of the multiple battery cells.

[0026] The foam forming process may include: a liquid foam solidification process that solidifies the liquid foam by causing the liquid foam to foam and solidify; and a foam kit exterior melting process that melts the bag-type ethylene cap on the outside of the foam kit by using the heat generated when the liquid foam foams and solidifies.

[0027] The battery cell can be a cylindrical secondary battery, and the foam formed by the foam forming process can uniformly fill the gaps between multiple battery cells in the vertical direction.

[0028] Technical effect

[0029] According to one embodiment of the present invention, during the manufacturing of the battery pack, the foam kit assembly can be fixed inside the battery pack housing, and then, during the assembly of the battery pack housing, the foam kit assembly is used to uniformly fill the interior of the battery pack housing with foam. Therefore, the uniformity of the foam inside the battery pack housing can be ensured, and the time required for battery pack manufacturing can be reduced. Attached Figure Description

[0030] Figure 1 This is an exploded perspective view showing a foam kit assembly and a battery pack including the foam kit assembly according to an exemplary embodiment.

[0031] Figure 2 This is a plan view showing the support frame and the pressing pin according to an exemplary embodiment.

[0032] Figure 3 This is an exploded perspective view showing a foam kit component according to an exemplary embodiment.

[0033] Figure 4 This is a schematic diagram illustrating a foam kit according to a variant of an exemplary embodiment.

[0034] Figure 5 This is a view illustrating the liquid foam diffusion process and foam formation process of a method for manufacturing a battery pack including a foam kit assembly according to an exemplary embodiment.

[0035] Figure 6 This is a view used to explain the foam formation process according to an exemplary embodiment. Detailed Implementation

[0036] In the following, embodiments of the invention will be described in detail with reference to the accompanying drawings. However, the invention may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to make this disclosure thorough and complete, and to fully convey the scope of the invention to those skilled in the art. In the drawings, the dimensions of layers and regions are exaggerated for clarity. The same reference numerals always denote the same elements.

[0037] In the following description, embodiments of the inventive concept will be described with reference to the accompanying drawings.

[0038] 1. A battery pack including a foam kit assembly according to an exemplary embodiment.

[0039] Figure 1 This is an exploded perspective view showing a foam kit assembly and a battery pack including the foam kit assembly according to an exemplary embodiment. Figure 2 This is a plan view showing the support frame and the pressing pin. Figure 3 This is an exploded perspective view showing a foam kit component according to an exemplary embodiment.

[0040] Reference Figures 1 to 3 A battery pack including a foam kit assembly is described according to an exemplary embodiment.

[0041] A battery pack according to an exemplary embodiment may include a battery pack housing 100, a plurality of battery cells 200, a foam kit assembly 300, and foam f.

[0042] 1.1. Battery pack casing 100

[0043] The battery pack housing 1030 may have an internal space to accommodate a plurality of battery cells 200 therein. The battery pack housing 100 may be rectangular cylindrical. Alternatively, the battery pack housing 100 may have various shapes. A plurality of battery cells 200, a foam kit assembly 300, and foam f may be accommodated in the battery pack housing 100. Here, the plurality of battery cells 200 may be disposed below the foam kit assembly 300. Furthermore, the foam f may entirely surround the plurality of battery cells 200, and simultaneously surround each of the plurality of battery cells 200. Specifically, the foam f may fill the space between the plurality of battery cells 200 and the inner surface of the battery pack housing 100, and simultaneously fill the gaps S between the plurality of battery cells 200.

[0044] The battery pack housing 100 may include an outer shell 110 with an upward opening inside and a top cover 120 mounted to the upper opening of the outer shell to press the foam kit assembly 300 in a downward direction.

[0045] The housing 110 may include: a lower plate 111 having a plate-like shape with a predetermined area for mounting a plurality of battery cells 200 thereon; and an upper frame 112 having a rectangular cylindrical shape extending along the circumference of the lower plate 111 and having a predetermined height above, for example, the height of the plurality of battery cells 200.

[0046] The top cover 120 can extend horizontally and has a predetermined area to be placed on the upper end of the upper frame 112.

[0047] 1.2. Multiple battery cells 200

[0048] Multiple battery cells 200 can be housed within the internal space of the battery pack housing 100 and arranged horizontally. Each of the multiple battery cells 200 can be a cylindrical secondary battery cell extending vertically.

[0049] The secondary battery cell can be configured such that an electrode assembly is housed within a battery casing. In this electrode assembly, a separator is disposed between a positive electrode plate to which a positive terminal is attached and a negative electrode plate to which a negative terminal is attached, and the positive electrode plate, negative electrode plate, and separator are wound in a core-like manner. Electrode terminals can be formed on each of two sides of the secondary battery cell: one side and the opposite side. Here, when a positive terminal is formed on one side of the secondary battery cell, a negative terminal can be formed on the opposite side.

[0050] For example, since multiple battery cells 200 are arranged in both row and column directions, the battery cells arranged in the row direction are arranged such that the positive and negative terminals are alternately facing upwards, and the battery cells arranged in the column direction are arranged such that the same electrode terminals are facing upwards. Therefore, the multiple battery cells 200 can be accommodated within the internal space of the battery pack housing 100. Furthermore, the multiple battery cells 200 can be connected in series in the row direction and in parallel in the column direction via busbars (not shown). However, the multiple battery cells 200 can have various arrangement structures and various connection methods. Here, the row direction can be the left-right direction, and the column direction can be the front-back direction. Both the left-right and front-back directions can be referred to as the horizontal direction. Furthermore, the direction intersecting the horizontal direction can be referred to as the vertical direction.

[0051] 1.3. Foam Kit Components 300

[0052] The foam kit assembly 300 is housed within the internal space of the battery pack housing 100 to be mounted on the plurality of battery cells 200 and isolated from the outside. Furthermore, when the foam kit assembly 300 is pressed upon contact with the battery pack housing 100, a portion of the foam kit assembly 300 may be punctured. Here, the punctured portion of the foam kit assembly 300 can serve as a channel through which liquid foam is discharged during battery pack manufacturing. In other words, the foam kit assembly 300 is used to supply liquid foam into the internal space of the battery pack housing 100.

[0053] 1.4. Detailed Construction of Foam Kit Component 300

[0054] The foam kit assembly 300 may include a support frame 310, a foam kit 320, and a pressure needle 330.

[0055] 1.4.1. Support Frame 310

[0056] The support frame 310 can be disposed on multiple battery cells 200. The support frame 310 can extend in a horizontal direction. The support frame 310 can allow the foam kit 320 to be placed on its top surface. The support frame 310 can have at least one opening to allow foam to pass through it.

[0057] The support frame 310 may include: a rod member 311, wherein at least one opening is formed in a grid shape; an edge member 312 for supporting the edge of the rod member 311; and a suspension member 313 that allows the edge member 312 to be positioned at the upper end of the upper frame 112 of the housing 110.

[0058] The rod member 311 may have a predetermined area on which the foam kit 320 is placed. The rod member 311 may be disposed inside the edge member 312, extending horizontally, and supported by the lower part of the edge member 312. Furthermore, at least one opening may be formed in a grid shape within the rod member 311. For example, the rod member 311 may include a plurality of first rods extending in a left-right direction and a plurality of second rods extending in a front-back direction. Here, the plurality of first rods and the plurality of second rods may be arranged in a grid shape and connected to each other.

[0059] Edge member 312 may extend along the inner periphery of the upper opening of housing 110. Edge member 312 may have, for example, a rectangular frame shape. Edge member 312 may be inserted into the upper opening of housing 110 and contact the inner surface of the upper opening of housing 110.

[0060] The suspension member 313 can be formed by bending outward from the upper end of the edge member 312. That is, the suspension member 313 can have a rectangular ring shape. The suspension member 313 can have a bottom surface disposed on the upper end of the upper frame 112. The top cover 120 can be disposed on the top surface of the suspension member 313.

[0061] Alternatively, the suspension member 313 may be inserted into the upper opening of the housing 110. In this case, the edge member 312 may be spaced apart from the inner surface of the upper opening of the housing 110, and the top cover 120 may be positioned on the upper end of the upper frame 112 of the housing 110.

[0062] 1.4.2. Foam Kit 320

[0063] The foam kit 320 can be mounted on the support frame 310, thereby contacting the top cover 120 and being pressed downward, and has a receiving space formed therein for containing liquid foam. That is, when manufacturing the battery pack, the foam kit 320 temporarily stores liquid foam therein and injects the liquid foam therein into the internal space of the battery pack housing 100.

[0064] The vertical thickness t2 of the foam kit 320 can be greater than the vertical thickness t1 of the edge member 312. Therefore, when the top cover 120 is assembled to the upper opening of the housing 110, the foam kit 320 can contact the bottom surface of the top cover 120 and be pressed downward.

[0065] Alternatively, the vertical thickness t2 of the foam kit 320 can be equal to the vertical thickness t1 of the edge member 312. In this case, the foam kit 320 can be positioned on the pressing pin 330 to protrude upward from the edge member 312 by a predetermined height, and when the top cover 120 is assembled to the upper opening of the housing 110, the foam kit 320 can contact the bottom surface of the top cover 120 and be pressed downward.

[0066] When the vertical thickness t2 of the foam kit 320 is less than the vertical thickness t1 of the edge member 312, the protrusion height of the pressing needle 330 can be determined such that when the foam kit 320 is placed on the pressing needle 330, the foam kit 320 protrudes upward from the edge member 312 by a predetermined height.

[0067] By using the foam kit 320, the battery pack housing 100 may not include a port for injecting liquid foam, and can have a simplified structure in the exemplary embodiment. Furthermore, by using the foam kit 320, the battery pack manufacturing process can be simplified because the liquid foam moves within the battery pack housing 100 in the exemplary embodiment, and the battery pack manufacturing facility can be simplified because no means for forcibly injecting liquid foam from the outside into the battery pack housing 100 are used.

[0068] The foam kit 320 may include a bag-type ethylene cap 321 and at least one storage chamber 322 formed in the bag-type ethylene cap 321 to contain liquid foam.

[0069] The liquid foam can be a single-component liquid foam and includes various materials that foam and solidify upon contact with air. When the liquid foam is contained in the storage chamber 322, it remains liquid because contact with air is blocked by the bag-type ethylene cap 321. When the bag-type ethylene cap 321 ruptures, the liquid foam may foam and solidify as it leaks into the internal space of the battery pack housing 100. Here, a predetermined amount of heat can be generated.

[0070] A pouch-type ethylene cap 321 may be disposed on the rod member 311. When a portion of the pouch-type ethylene cap 321 is broken by the pressing needle 330, the pouch-type ethylene cap 321 temporarily stores liquid foam therein and discharges the liquid foam therein into the internal space of the battery pack housing 100. The pouch-type ethylene cap 321 may have a predetermined thickness and includes a predetermined material that melts at the temperature generated during the foaming and solidification of the liquid foam. Therefore, when foam f is formed due to the complete foaming and solidification of the liquid foam, at least a portion of the pouch-type ethylene cap 321 can be melted and removed by heating.

[0071] 1.4.3. Press the needle 330

[0072] The pressing pin 330 protrudes from the support frame 310 to penetrate the foam kit 320. Specifically, the pressing pin 330 may protrude upward from multiple locations on the top surface of the rod member 331, so that when the battery pack housing 100 is assembled, the pressing pin 330 can penetrate the bottom surface of the foam kit 320. The pressing pin 330 may have a tapered shape. Alternatively, the pressing pin 330 may have various shapes.

[0073] Here, a gap can be formed between the outer circumferential surface of the pressing needle 330 and the penetrating portion of the foam kit 320 to allow liquid foam to flow through, and the liquid foam in the foam kit 320 can flow downward through this gap.

[0074] Multiple battery cells 200 can be grouped according to their horizontal positions. Furthermore, multiple pressing pins 330 can be provided to be aligned vertically with the center of each of the multiple groups, and the multiple pressing pins 330 can be spaced apart from each other. Therefore, when manufacturing the battery pack, the aforementioned gaps that allow liquid foam to flow through can be evenly spaced apart in the horizontal direction, and the liquid foam is supplied to the multiple battery cells 200.

[0075] 1.5. Foam f

[0076] Foam f is discharged from foam kit assembly 300 and fills the space between the inner surface of battery pack housing 100 and foam kit assembly 300. Here, foam f can be discharged downward from the penetration portion of foam kit 320 created by pressing pin 330 and fill the gap S between the plurality of battery cells 200 in the vertical direction. That is, foam f is discharged from the penetration portion, forms a solid due to the foaming and solidification of liquid foam, and surrounds each of the plurality of battery cells 200.

[0077] 1.6. Foam kit according to a variant of the exemplary embodiment

[0078] Figure 4 This is a schematic diagram illustrating a foam kit according to a variant of an exemplary embodiment.

[0079] Reference Figure 4 The foam kit 320' according to a variant of the exemplary embodiment includes: a bag-type ethylene cap 321; a plurality of storage chambers 322a and 322b formed in the bag-type ethylene cap 321 to contain liquid foam; and a separation membrane 323 disposed in the bag-type ethylene cap 321 to separate the plurality of storage chambers 322a and 322b and is broken by pressure applied to the bag-type ethylene cap 321 from the top cap 120.

[0080] Here, the liquid foam can be a two-component liquid foam. That is, the liquid foam can include a base material and a curing agent. In this case, when foam f is formed, the base material and curing agent are separated and then mixed. Therefore, the bag-type vinyl cap 321 can include multiple storage chambers 322a and 322b, in which the base material and curing agent of the two-component liquid foam can be contained, respectively, and then the base material and curing agent can be mixed with each other when the separation membrane 323 ruptures. Furthermore, the separation membrane 323 can have a predetermined thickness that is easier to rupture than the bag-type vinyl cap 321, and when the bag-type vinyl cap 321 is pressed by the top cap 120, the separation membrane 323 can rupture before the pressing needle 330 penetrates the bag-type vinyl cap 321.

[0081] 1.7. Battery pack housing according to another variant of the exemplary embodiment

[0082] Because the foam kit 320 is penetrated by the pressing needle 330, the liquid foam flows downward through the gap therebetween. Here, the liquid foam flows from the upper part of the battery cell to the lower part. Here, the air present around the lower part of the battery cell can be isolated by the liquid foam at the lower part of the battery pack housing 100, instead of being discharged to the upper side of the liquid foam. Furthermore, when the liquid foam solidifies simultaneously during foaming and curing, a predetermined gas can be discharged, and the discharged gas can be isolated at the lower part of the battery pack housing 100.

[0083] According to another variant of the exemplary embodiment, the outer casing 110 of the battery pack housing may include a predetermined pneumatic pressure regulating hole (not shown) to allow air and gas to move smoothly to the upper part of the battery pack housing 100.

[0084] Specifically, the housing 110 may include a lower plate 111 having a region on which a plurality of battery cells 200 are disposed, and an upper frame 112 extending along the periphery of the lower plate 111 and having a height greater than the height of each of the plurality of battery cells 200. Here, a pneumatic pressure regulating hole may extend inside the lower plate 111 and inside the upper frame 112, and has an inlet formed in the top surface of the lower plate 111 and an outlet formed in the inner circumferential surface or the outer circumferential surface of the upper end of the upper frame 112. At least one pneumatic pressure regulating hole may be formed.

[0085] The pneumatic pressure regulating hole prevents air or gas from being isolated in the lower part of the battery pack housing 100, so that liquid foam can flow smoothly to the top surface of the lower plate 111.

[0086] 2. A method for manufacturing a battery pack including a foam kit assembly according to an exemplary embodiment.

[0087] Figure 5 This is a view illustrating the liquid foam diffusion process and foam formation process of a method for manufacturing a battery pack including a foam kit assembly according to an exemplary embodiment. Figure 6 This is a view used to explain the foam formation process according to an exemplary embodiment.

[0088] Reference Figures 1 to 6 A method for manufacturing a battery pack including a foam kit assembly according to an exemplary embodiment is described. Here, when describing the method for manufacturing a battery pack including a foam kit assembly, features that overlap with the above description of a battery pack including a foam kit assembly according to an exemplary embodiment will be omitted or briefly described.

[0089] A method for manufacturing a battery pack including a foam kit assembly according to an exemplary embodiment may include the following processes.

[0090] 2.1. Battery cell storage process

[0091] The battery cell storage process involves storing multiple battery cells 200 arranged horizontally and each extending vertically within an internally upward-opening housing 110. Each of the multiple battery cells 200 can be a cylindrical secondary battery. The multiple battery cells 200 can be electrically connected to each other via busbars (not shown). The multiple battery cells 200 can be spaced apart by a predetermined distance to form a gap S therebetween.

[0092] 2.2. Foam Kit Component Arrangement Process

[0093] The foam kit assembly placement process involves placing a foam kit assembly 300 containing liquid foam onto multiple battery cells 200.

[0094] The foam kit assembly arrangement process may include: a support frame arrangement process for placing the support frame 310 of the foam kit assembly 300 on the plurality of battery cells 200; a foam kit arrangement process for placing the foam kit 320 of the foam kit assembly 300 on the support frame 310; and a press pin contact process that allows the foam kit 320 to contact the press pin 330 of the foam kit assembly 300 protruding from the support frame 310. During this process, since the foam kit 320 is not pressed by the top cover, the foam kit 320 can be positioned on the press pin 330.

[0095] 2.3. Battery Pack Casing Assembly Process

[0096] The battery pack housing assembly process is performed by attaching the top cover 120 to the upper opening of the housing 110.

[0097] For example, in a structure where the suspension member 313 of the support frame 310 is positioned around the periphery of the upper opening of the housing, the top cover 120 can be positioned and mounted on the top surface of the suspension member 313. In a structure where the suspension member 313 of the support frame 310 is inserted into the upper opening of the housing, the top cover 120 can be positioned and mounted on the upper end of the upper frame 112 of the housing 110. The liquid foam diffusion process can be performed simultaneously with the battery pack housing assembly process. That is, in the exemplary embodiment, the liquid foam diffusion process can be performed quickly by assembling the battery pack housing 100, thus reducing the overall manufacturing process of the battery pack.

[0098] 2.4. Liquid foam diffusion process

[0099] The liquid foam diffusion process performs the process of diffusing liquid foam from the interior of the foam kit 320 of the foam kit assembly 300 into the entire interior space of the battery pack housing 100, such that the foam kit 320 of the foam kit assembly 300 contacts the bottom surface of the top cover 120 to press the foam kit 320, and a portion of the foam kit 320 of the foam kit assembly 300 is penetrated by the pressing needle 330.

[0100] The liquid foam diffusion process includes: a foam kit pressing process by pressing the foam kit 320 downward through the top cover 120; a discharge hole forming process by forming a discharge hole by causing the pressing needle 330 to penetrate the bottom surface of the foam kit 320; and a liquid foam discharge process by discharging the liquid foam contained in the foam kit 320 onto the plurality of battery cells 200 through the gap between the discharge hole and the outer peripheral surface of the pressing needle 330.

[0101] In other words, while assembling the battery pack housing 100 by attaching the top cover 120 to the housing 110, the pressing needle 330 can penetrate the bottom surface of the foam kit 320 by pressing the foam kit 320 with the top cover 120. Therefore, multiple through holes (e.g., drainage holes) can be formed in the bottom surface of the foam kit 320, and the liquid foam temporarily stored in the foam kit 320 can be smoothly discharged downward through the gap between the pressing needle 330 and the through holes.

[0102] Alternatively, the liquid foam diffusion process may include: a liquid foam diffusion process that diffuses liquid foam onto a plurality of battery cells 200 in a horizontal direction; and a liquid foam flow process that guides the liquid foam to flow downwards from the upper part to the lower part of each of the plurality of battery cells 200. That is, the liquid foam discharged onto the plurality of battery cells 200 through the through-holes may have a predetermined viscosity. The liquid foam may be uniformly distributed on the plurality of battery cells 200 in a horizontal direction because the liquid foam flows more easily in a horizontal direction before flowing downwards into the gaps between the plurality of battery cells 200. Here, at least one opening with a grid shape may be formed in the rod member 311. Thereafter, the liquid foam may flow downwards from the upper part to the lower part of each of the plurality of battery cells 200 through the gaps S between the plurality of battery cells 200. Here, the liquid foam may be uniformly filled into the gaps S between the plurality of battery cells 200 in a vertical direction. The foam formation process may be performed simultaneously with the liquid foam dispersion process and the liquid foam flow process.

[0103] 2.5. Foam Formation Process

[0104] The foam formation process can be performed by foaming and solidifying liquid foam in the internal space of the battery pack housing 100 to form solidified foam f between the inner surface of the battery pack housing 100 and the foam kit assembly 300.

[0105] In other words, the foam formation process can include: a liquid foam solidification process by causing liquid foam to foam and solidify; and a foam kit exterior melting process by using the heat generated when the liquid foam foams and solidifies (e.g., heat of about 40°C) to melt the bag-type vinyl cover 321 of the exterior of the foam kit 320. The liquid foam can foam and solidify by contact with air in the battery pack housing 100, or by mixing a base material with a curing agent. When the bag-type vinyl cover 321 of the foam kit 320 is heated and melted, foam f can be formed even in the space occupied by the bag-type vinyl cover 321. Alternatively, only a portion of the bag-type vinyl cover 321 may be heated and melted and removed, or the entire bag-type vinyl cover 321 may be retained on the support frame 310.

[0106] The foam f formed by the foam forming process can uniformly fill the gap S between multiple battery cells 200 in the vertical direction, prevent heat transfer between multiple battery cells 200 after solidification, and guide the material leaking from the ruptured battery cell to flow away from another battery cell to prevent short circuit between multiple battery cells 200.

[0107] The above-described embodiments of the present invention are for illustrative purposes only and are not intended to limit the invention. It should be understood that the configurations and methods disclosed in the above embodiments of the present invention can be combined and modified into various forms through combination or intersection, and the resulting variations should also be considered within the scope of the present invention. The present invention will be implemented in various forms different from each other within the scope of the claims and their equivalents, and those skilled in the art will understand that various embodiments within the scope of the present invention's technical concept are feasible.

[0108] (See attached image labels)

[0109] 100: Battery pack casing

[0110] 110: Outer shell

[0111] 120: Top Cover

[0112] 200: Multiple battery cells

[0113] 300: Foam Kit Components

[0114] 310: Supporting Frame

[0115] 311: Rod Component

[0116] 312: Edge component

[0117] 313: Suspension components

[0118] 320: Foam Kit

[0119] 321: Pouch-type vinyl cap

[0120] 322: Storage Room

[0121] 330: Pressing needle

[0122] S: Gap

[0123] f: foam

[0124] F: Downward flow of liquid foam

Claims

1. A battery pack, the battery pack comprising: A battery pack housing having an internal space; Multiple battery cells, which are housed in the internal space of the battery pack housing, are arranged in a horizontal direction and each extends in a vertical direction; A foam kit assembly, which is housed in the internal space of the battery pack housing, such that the foam kit assembly is disposed on the plurality of battery cells and isolated from the outside; as well as Foam, which is discharged from the foam kit assembly and fills the space between the inner surface of the battery pack housing and the foam kit assembly. The foam kit component includes: A support frame is disposed on the plurality of battery cells and extends in a horizontal direction and has at least one opening, allowing liquid foam to pass through the support frame in a vertical direction. A foam kit, which is mounted on the support frame to contact and be pressed by the top cover of the battery pack housing, and has a receiving space formed within the foam kit for accommodating the liquid foam; and A pressure pin protrudes from the support frame to penetrate the foam assembly. The foam is formed such that the liquid foam flows downward from the receiving space of the foam kit through the through-hole defined by the pressing pin of the foam kit to form the foam on the bottom surface of the outer casing of the battery pack housing.

2. The battery pack according to claim 1, wherein, The foam kit has a top surface and a bottom surface, the top surface being in contact with the top cover and pressed down by the top cover, and the bottom surface being penetrated by the pressing needle.

3. The battery pack according to claim 2, wherein, The battery pack housing includes: The outer casing, the interior of which opens upwards; and The top cover is mounted to the upper opening of the housing to press down on the foam kit of the foam kit assembly.

4. The battery pack according to claim 3, wherein, The foam solidifies through the foaming and curing of the liquid foam, and uniformly fills the gaps between the multiple battery cells in the vertical direction while surrounding the multiple battery cells.

5. The battery pack according to claim 4, wherein, The support frame supports the discharge from the through-holes of the foam kit and forms the upper shape of the foam between the plurality of battery cells. The supporting frame includes: An edge member extending along the inner periphery of the upper opening of the housing; and A rod member is disposed inside the edge member such that the foam kit is placed on the rod member and extends in the horizontal direction to be supported by the edge member, and in the rod member, the at least one opening is formed in a grid shape.

6. The battery pack according to claim 5, wherein, The support frame also includes a suspension member that allows the edge member to be positioned at the upper end of the upper frame of the housing.

7. The battery pack according to claim 6, wherein, The suspension member is formed by bending outward from the upper end of the edge member.

8. The battery pack according to claim 5, wherein, The pressing pins protrude upwards from multiple locations on the top surface of the rod member. The bottom surface of the foam kit is pierced by the pressing needle, and A gap is formed between the penetrated portion of the foam kit and the outer peripheral surface of the pressing needle, through which the liquid foam flows downward.

9. The battery pack according to claim 4, wherein, The plurality of battery cells are divided into multiple groups based on their horizontal position, and The pressing needles are configured as a plurality of pressing needles, such that the plurality of pressing needles are aligned vertically with the center position of each of the plurality of groups and spaced apart from each other in the horizontal direction.

10. The battery pack according to claim 4, wherein, The foam kit includes: Pouch-type vinyl cap; and At least one storage chamber, formed within the bag-type ethylene cap, to contain the liquid foam. The liquid foam is a single-component liquid foam.

11. The battery pack according to claim 10, wherein, The bag-type ethylene cap has a predetermined thickness and includes a predetermined material that melts at the temperature generated during the foaming and curing of the liquid foam.

12. The battery pack according to claim 4, wherein, The foam kit includes: Pouch-type vinyl cap; Multiple storage chambers, formed within the bag-type ethylene cap, to contain the liquid foam; and A separation membrane, disposed within the bag-type ethylene cap, divides the interior of the bag-type ethylene cap into multiple storage chambers and ruptures upon pressure applied to the bag-type ethylene cap from the top cap. Wherein, the liquid foam is a two-component liquid foam, and The base material and curing agent of the two-component liquid foam are respectively contained in the plurality of storage chambers.

13. The battery pack according to claim 10 or 12, wherein, The bag-type ethylene cap melts at the temperature of the heat generated during the foaming and curing of the liquid foam.

14. The battery pack according to claim 3, wherein, The outer casing includes: Lower plate, the lower plate having an area on which the plurality of battery cells are disposed; and An upper frame extends along the periphery of the lower plate and has a height greater than the height of each of the plurality of battery cells. The battery pack further includes at least one pneumatic pressure regulating hole, which extends inside the lower plate and the upper frame, and has an inlet formed in the top surface of the lower plate and an outlet formed in the inner or outer circumferential surface of the upper end of the upper frame.

15. A method for manufacturing a battery pack, the method comprising: The battery cell storage process involves storing multiple battery cells arranged horizontally and each extending vertically within an internally upward-opening casing. The foam kit assembly arrangement process involves arranging foam kit assemblies containing liquid foam on the plurality of battery cells; The battery pack housing assembly process involves assembling the battery pack housing by attaching a top cover to the upper opening of the housing; The liquid foam diffusion process allows a portion of the foam kit assembly to be penetrated when the foam kit assembly contacts and is pressed by the top cover, and diffuses the liquid foam from the foam kit assembly into the entire interior space of the battery pack housing; as well as A foam formation process that forms foam between the inner surface of the battery pack housing and the foam kit assembly by foaming and solidifying the liquid foam.

16. The method according to claim 15, wherein, The foam kit assembly arrangement process includes: The support frame placement process involves placing the support frame of the foam kit assembly onto the plurality of battery cells; The foam kit placement process involves placing the foam kit assembly onto the support frame; and The press needle contact process allows the foam kit and the press needles of the foam kit assembly protruding from the support frame to come into contact with each other.

17. The method according to claim 16, wherein, The liquid foam diffusion process includes: The foam kit pressing process involves pressing the foam kit downwards through the top cover; The process of forming a discharge hole involves creating a discharge hole by allowing the pressing pin to penetrate the bottom surface of the foam assembly; and The liquid foam discharge process discharges the liquid foam contained in the foam kit onto the plurality of battery cells through the gap between the discharge hole and the outer peripheral surface of the pressing needle.

18. The method according to claim 17, wherein, The liquid foam diffusion process also includes: The liquid foam dispersing process horizontally disperses the liquid foam onto the plurality of battery cells; and The liquid foam flow process guides the liquid foam to flow downwards from the top to the bottom of each of the plurality of battery cells.

19. The method of claim 17, wherein, The foam formation process includes: A liquid foam solidification process that solidifies the liquid foam by foaming and solidifying it; and The foam kit exterior melting process uses the heat generated when the liquid foam foams and solidifies to melt the bag-type ethylene cap that serves as the exterior of the foam kit.

20. The method according to claim 18, wherein, The battery cell is a cylindrical secondary battery, and The foam formed by the foam forming process uniformly fills the gaps between the plurality of battery cells in the vertical direction.

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