High-heat-resistant connector, and battery module, battery pack, and vehicle including the same

Abstract

A heat-resistant connector, and a battery module, a battery pack, and a vehicle including the same are provided. A battery module according to the present invention includes a cell assembly including at least one battery cell, a module case accommodating the cell assembly, and a connector mounted on the module case. The connector includes a connector terminal electrically connected with the battery cell, a connector housing configured to surround the connector terminal, and a connector head body coupled to the connector housing and at least partially inserted into the module case to be mounted on the module case. Here, the connector head body is formed of a heterogeneous composite material including a heat-resistant metal material having a melting point of 1000℃ or more and a lightweight metal material that is lighter than the heat-resistant metal material.

Description

Technical Field

[0001] This disclosure relates to battery modules, battery packs including the battery modules, and vehicles, and more particularly to battery modules including improved connectors, battery packs including the battery modules, and vehicles. This application claims priority to Korean Patent Application No. 10-2021-0125999, filed in Korea on September 23, 2021, the disclosure of which is incorporated herein by reference. Background Technology

[0002] Because of their versatility due to their product mix and electrical characteristics such as high energy density, rechargeable batteries are commonly used not only in mobile devices but also in electric or hybrid vehicles powered by electric power sources, energy storage systems, and more. Since rechargeable batteries can fundamentally reduce the use of fossil fuels and produce no byproducts associated with energy consumption, they are gaining attention as a new alternative energy source for improving eco-friendliness and energy efficiency.

[0003] A battery pack for use in electric vehicles and the like has a structure in which multiple cell assemblies are connected in series to obtain high power, the multiple cell assemblies including multiple secondary battery cells. Each battery cell includes a positive current collector and a negative current collector, a separator, active materials, and an electrolyte, and can be repeatedly charged and discharged through electrochemical reactions between the elements.

[0004] With the recent increase in demand for high-capacity structures used as energy storage sources, there is also an increased demand for battery packs with multi-module structures having multiple battery cells connected in series and / or parallel. When configuring a battery pack, the general approach is to first configure a battery module including at least one battery cell and then add other components using that at least one battery module to configure the battery pack. The number of battery modules included in the battery pack, or the number of battery cells included in a battery module, can be set in various ways depending on the required output voltage or charge / discharge capacity.

[0005] A battery module encapsulates battery cells and various electronic components within a module housing, and includes connectors for electrical connection to external devices outside the module housing. These connectors can be connection connectors for electrically connecting multiple battery modules, sensing connectors for monitoring the voltage of the battery cells, charging connectors for connecting to a charging device for charging the battery cells, or output connectors for connecting to a motor driven by energy charged within the battery cells.

[0006] Because conventional battery modules are manufactured with multiple battery cells densely packed into a narrow space, preventing fires and other hazards is important. In particular, when such battery modules and battery packs including them are used in vehicles, rigorous safety testing is necessary.

[0007] In existing battery modules, most of the connectors, except for the connector terminals, are manufactured using conventional plastic injection molding. When abnormally high temperatures occur in a battery module using such connectors, the connectors are prone to melting. In particular, battery modules equipped with such connectors, or battery packs as a group of battery modules, may fail the thermal runaway test. The thermal runaway test, according to GB standards, requires a battery pack or system to provide a thermal event warning signal 5 minutes before thermal runaway occurs, which could lead to a hazard in the vehicle's passenger compartment.

[0008] Therefore, in order to meet GB standards, connectors are absolutely required to prevent the spread of high-temperature environments caused by flames and / or high-pressure environments caused by exhaust. Summary of the Invention

[0009] Technical issues

[0010] In view of the above problems, this disclosure was designed, and therefore this disclosure aims to provide an improved connector that prevents the diffusion of high-temperature environments caused by flames or the like in the battery module and / or high-pressure environments caused by exhaust gases from the battery module to the outside.

[0011] This disclosure also relates to providing a battery module including an improved connector.

[0012] This disclosure also relates to providing battery packs and vehicles including the battery modules to improve safety in the event of fire or explosion.

[0013] However, the technical objectives to be addressed by this disclosure are not limited to those described above, and those skilled in the art can clearly understand other objectives not mentioned herein based on the following disclosure.

[0014] Technical solution

[0015] In one aspect of this disclosure, a connector is provided, the connector comprising: a connector terminal; a connector housing surrounding the connector terminal; and a connector headerbody coupled to the connector housing, the connector headerbody being formed of a heterogeneous composite material comprising a heat-resistant metal material having a melting point of 1000°C or higher and a lightweight metal material lighter than the heat-resistant metal material.

[0016] The connector head body may include a first part and a second part, the first part being relatively far from the connector housing and formed of the heat-resistant metal material, and the second part being closer to the connector housing than the first part and formed of the lightweight metal material.

[0017] The connector head body may include a first part and a second part, the first part being relatively far from the connector housing and formed of stainless steel (SUS metal), and the second part being closer to the connector housing than the first part and formed of an aluminum-based metal material.

[0018] Heterogeneous composite materials can be clad metals.

[0019] In another aspect of this disclosure, a battery module is provided, the battery module comprising: a cell assembly including at least one battery cell; a module housing housing the cell assembly; and a connector mounted on the module housing. The connector comprises: connector terminals for electrical connection to the battery cell; a connector housing surrounding the connector terminals; and a connector head body coupled to the connector housing and mounted on the module housing such that at least a portion of the connector head body is inserted into the module housing, the connector head body being formed of a heterogeneous composite material comprising a heat-resistant metal material with a melting point of 1000°C or higher and a lightweight metal material lighter than the heat-resistant metal material.

[0020] The connector head body may include a first part and a second part, the first part facing the battery cell assembly inside the module housing and being formed of a heat-resistant metal material, and the second part facing the outside of the module housing and being formed of a lightweight metal material.

[0021] The connector head body may include a first part and a second part, the first part facing the battery cell assembly inside the module housing and being formed of stainless steel (SUS metal), and the second part facing the outside of the module housing and being formed of an aluminum-based metal material.

[0022] In the connector head body, the heat-resistant metal material can face the battery cell assembly inside the module housing, and the melting point of the heat-resistant metal material can be 1400℃ or higher.

[0023] An opening is formed in the module housing, and the connector head body can contact the surface of the module housing within the opening, and bolts can be tightened to keep the opening airtight.

[0024] The connector head body may include a first part and a second part, the first part facing the battery cell assembly inside the module housing and being formed of a heat-resistant metal material, and the second part facing the outside of the module housing and being formed of a lightweight metal material.

[0025] The connector housing can be connected to the connector head body by press fitting or hook fastening.

[0026] The connector housing and connector head body can be a single, integrally formed product.

[0027] The battery module may also include a sealing gasket located between the module housing and the connector head body and having a melting point of 1000°C or higher.

[0028] An opening may be formed in the module housing, and the connector head body may contact the surface of the module housing within the opening via a sealing gasket to maintain the opening airtight.

[0029] The sealing gasket may have a frame shape, the frame shape having a hollow portion of the same size as the opening.

[0030] The sealing gasket and the connector head body can be fastened to the module housing using bolts.

[0031] The sealing gasket can be a silicone resin gasket.

[0032] In another aspect of this disclosure, a battery pack including at least one battery module and a vehicle including at least one battery pack are provided.

[0033] Beneficial effects

[0034] According to this disclosure, an improved connector (i.e., a high-heat resistant connector) and a battery module including the connector are provided, wherein the high-temperature environment caused by a flame in the battery module and / or the high-pressure environment caused by exhaust gases in the battery module are prevented from spreading to the outside.

[0035] Because the battery module according to this disclosure includes a connector comprising a connector head body made of a heat-resistant metal material with a melting point of 1000°C or higher, the flame can be prevented from spreading to the outside of the battery module even if a flame appears in the battery module and thus causes an abnormally high temperature state. Furthermore, even if exhaust gases are generated in the battery module and thus cause an abnormally high pressure state, an explosion through the connector can be prevented.

[0036] In particular, as proposed in this disclosure, when heterogeneous composite materials are applied to connectors such that only the portion exposed to the flame inside the battery module is formed of a heat-resistant metal material, and the remaining portion is formed of a lightweight metal material that is lighter than the heat-resistant metal material, airtightness, heat resistance and weight reduction can be achieved.

[0037] Therefore, according to this disclosure, a battery module including a high-temperature resistant connector is provided, wherein the hermetically sealed structure of the battery module is maintained even in the event of thermal runaway and it can withstand high-temperature / high-pressure environments. Due to the application of heterogeneous composite materials, weight and cost can be reduced compared to the use of a single metal connector.

[0038] Furthermore, because the battery module according to this disclosure includes a sealing gasket with a melting point of 1000°C or higher, the effect of preventing flames from spreading to the outside of the battery module can be maximized.

[0039] For example, even when the temperature adjacent to the module housing rises to approximately 600°C (for at least 5 minutes), heat transfer can be prevented because the battery module, including the connector as described in this disclosure, can withstand high temperature / high pressure (100 kPa). Therefore, according to this disclosure, a battery module with improved safety, as well as a battery pack and vehicle including the battery module, can be provided. Attached Figure Description

[0040] The accompanying drawings illustrate preferred embodiments of the present disclosure and, together with the foregoing disclosure, serve to provide a further understanding of the technical features of the present disclosure; therefore, the present disclosure is not to be construed as limited to the drawings.

[0041] Figure 1 This is a schematic exploded perspective view showing a battery module according to an embodiment of the present disclosure.

[0042] Figure 2 A front view and an enlarged view of the connector portion of a battery module according to an embodiment of the present disclosure are shown.

[0043] Figure 3 This is a perspective view showing a connector portion separate from the battery module according to an embodiment of the present disclosure.

[0044] Figure 4 It is along Figure 2 The line IV-IV' intercepted Figure 1 A partial cross-sectional view.

[0045] Figure 5 It is along Figure 2 The line V-V' intercepted Figure 1 A partial cross-sectional view.

[0046] Figure 6This is a perspective view showing a connector portion separate from the battery module according to another embodiment of the present disclosure.

[0047] Figure 7 This is a perspective view illustrating a sealing gasket that may be included in a battery module according to another embodiment of the present disclosure.

[0048] Figure 8 This is a schematic diagram illustrating a battery pack according to an embodiment of the present disclosure.

[0049] Figure 9 This is a schematic diagram illustrating a vehicle according to an embodiment of the present disclosure.

[0050] Figures 10 to 12 This is a photo of a connector manufactured for experimental purposes.

[0051] Figure 13 and Figure 14 These are photos of test setups used to verify the connectors.

[0052] Figure 15 It is a graph showing the test results. Detailed Implementation

[0053] Preferred embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. Before the description, it should be understood that the terminology used in the specification and appended claims should not be construed as limited to its general and dictionary meaning, but rather as being interpreted based on the meaning and concepts corresponding to the technical aspects of the present disclosure, in accordance with the principle that inventors are allowed to appropriately define terms for the best interpretation.

[0054] Therefore, the description presented herein is merely a preferred example for illustrative purposes and is not intended to limit the scope of this disclosure. It should be understood that other equivalents and modifications can be made thereto without departing from the scope of this disclosure. Furthermore, to aid in understanding this disclosure, the accompanying drawings are not drawn to scale, and the dimensions of some components may be exaggerated.

[0055] Figure 1 This is a schematic exploded perspective view showing a battery module according to an embodiment of the present disclosure. Figure 2 A front view and an enlarged view of the connector portion of a battery module according to an embodiment of the present disclosure are shown. Figure 3 This is a perspective view showing a connector portion separate from the battery module according to an embodiment of the present disclosure. Figure 4 It is along Figure 2 The line IV-IV' intercepted Figure 1 A partial cross-sectional view. Figure 5 It is along Figure 2 The line V-V' intercepted Figure 1 A partial cross-sectional view.

[0056] First, refer to Figure 1 According to embodiments of the present disclosure, the battery module 10 includes a cell assembly 100, a module housing 150, and a connector 200.

[0057] The cell assembly 100 includes at least one battery cell. The at least one battery cell of the cell assembly 100 may be a pouch cell, and multiple battery cells may be stacked and arranged in the cell assembly 100. The multiple battery cells may be electrically connected to each other, and each battery cell may include an electrode assembly, a housing housing the electrode assembly, and electrode leads protruding outward from the housing and electrically connected to the electrode assembly.

[0058] The electrode leads may include positive and negative leads. The positive and negative leads may be located in opposite directions along the longitudinal direction of the battery cell, or they may be located in the same direction along the longitudinal direction of the battery cell. The positive and negative leads may be formed of various materials. For example, the positive lead may be formed of aluminum, and the negative lead may be formed of copper.

[0059] Electrode leads can be electrically connected via busbars (not shown). The battery cell can have the following structure: multiple unit cells arranged in the order of positive plate-separator-negative plate, or bicelles arranged in the order of positive plate-separator-negative plate-separator-positive plate-separator-negative plate, stacked according to capacity.

[0060] The cell assembly 100 can be configured such that multiple battery cells are stacked on top of each other. The battery cells can have any structure of various kinds, and multiple battery cells can be stacked in any way of various kinds.

[0061] The cell assembly 100 may include multiple boxes (not shown) for housing battery cells. Each box (not shown) may be manufactured using plastic injection molding, and multiple boxes including housing portions for housing battery cells may be stacked. Terminal elements may be provided in the box assembly of stacked boxes. The terminal elements, which are the main components for connection with the battery cells, include positive and negative terminals, and the terminal elements may be provided with terminal bolts for electrical connection to the outside. The battery cells may have any shape of various shapes.

[0062] The module housing 150 has an empty internal space. The module housing 150 accommodates the cell assembly 100 and forms the exterior of the battery module 10. The shape of the module housing 150 may correspond to the shape of the cell assembly 100 or the box assembly. For example, when the cell assembly 100 or the box assembly has a hexahedral shape, the module housing 150 may also have a hexahedral shape corresponding to the cell assembly 100 or the box assembly. Various electronic components may be included in the module housing 150, and may include, for example, an internal circuit board (ICB) or a battery management system (BMS). Electronic components such as the ICB and BMS may be electrically connected to multiple battery cells.

[0063] The module housing 150 can be manufactured by bending a sheet of metal material or by injection molding a plastic product. The module housing 150 can be manufactured integrally or as a separate type. Typically, the module housing 150 may have at least one surface opening through which the cell assembly 100 is inserted and then the opening is closed. The module housing 150 can be provided in a substantially rectangular parallelepiped shape.

[0064] The module housing 150 can have any of a variety of configurations. For example, the module housing 150 may include a U-shaped frame that houses the cell assembly 100 and has an open top, and a top plate located on the U-shaped frame to cover the cell assembly 100. The top surface, front surface, and rear surface of the U-shaped frame are open, and therefore, end plates may be located on each of the front and rear surfaces of the U-shaped frame to cover the front and rear openings.

[0065] In another example, the module housing 150 may include a rectangular tubular single frame and a front cover and a rear cover, wherein two facing sides of the rectangular tubular single frame are open, and the front cover and the rear cover cover the two facing sides of the single frame. This disclosure does not limit the specific structure of the module housing 150.

[0066] Connector 200 is mounted on module housing 150. Connector 200 can be mounted on a portion of the cell assembly 100 housed within module housing 150 for easy electrical connection. For example, connector 200 can be mounted near the electrode leads of the battery cells included in cell assembly 100. For example, as shown, the connector can be mounted on an end plate, front cover, or rear cover adjacent to a portion of the battery cell's electrode leads that may be located within module housing 150. Connector 200 can be provided as any of various types of electrical connection components or connecting members for connection to a BMS that can provide data related to the voltage or temperature of the battery cells in battery module 10. Connector 200 is coupled to module housing 150 to transmit data regarding voltage or temperature to the outside.

[0067] Reference Figure 2 and Figure 3 The connector 200 includes connector terminals 210, connector housing 220, and connector head body 230.

[0068] Connector terminal 210 is used to electrically connect a component disposed on one side of connector 200 to another component disposed on the other side of connector 200. In this embodiment, connector 200 is a sensing connector for monitoring the voltage of battery cells, and connector terminal 210 is used to electrically connect to the battery cells of cell assembly 100. A transmission plug (not shown) for connecting data related to the voltage of the battery cells of cell assembly 100 to BMS can be connected to connector terminal 210. Connector terminal 210 may include a conductive material such as copper (Cu).

[0069] Connector housing 220 surrounds connector terminal 210. Connector housing 220 may accommodate connector terminal 210 and may expose one end.

[0070] Connector housing 220 is attached to connector head body 230. Connector housing 220 may be a separate component from connector head body 230 manufactured by plastic injection molding. Connector housing 220 may be attached to connector head body 230 by press-fit or hook fastening.

[0071] The connector head body 230 can expose the ends of the connector terminals 210 exposed from the connector housing 220. The connector head body 230 can be mounted on the module housing 150 such that at least a portion of the connector head body 230 is inserted into the module housing 150, and the connector housing 220 remains outside the module housing 150. The connector terminals 210 can pass through the connector housing 220 and the connector head body 230. A hole can be formed in the connector head body 230 such that the connector terminals 210 pass through the hole. The connector terminals 210 can be inserted into the module housing 150 through the hole in the connector head body 230.

[0072] The connector head body 230 is attached to the module housing 150. The connector head body 230 can be attached to the module housing 150 by any of a variety of methods.

[0073] Reference Figure 4 and Figure 5 An opening 152 is formed in the module housing 150, and the connector head body 230 contacts the surface of the module housing 150 within the opening 152, and a fastening bolt 240 is tightened to maintain an airtight opening 152. A fastening hole through which the bolt 240 passes can be formed in the connector head body 230.

[0074] All parts of the module housing 150 except for the opening 152 can be sealed using a welding process. In this case, the part most exposed to flame and gas is the connector 200 when thermal runaway occurs in the battery module 10. According to this disclosure, the connector 200 can be improved to prevent the high-temperature environment caused by the flame in the battery module 10 and / or the high-pressure environment caused by the exhaust gas in the battery module 10 from spreading to the outside.

[0075] When the connector housing 220 is attached to the connector head body 230, the connector housing 220 can be exposed through the opening 152 inside the module housing 150, and then the module housing 150 and the connector head body 230 can be fastened to each other using bolts 240. Conversely, the connector head body 230 can be in contact with the surface of the module housing 150 inside the module housing 150, and the bolts 240 can be fastened to the outside of the module housing 150, and then the connector housing 220 can be attached to the connector head body 230 from the outside of the module housing 150.

[0076] The opening 152 may be large enough to be secured by the connector housing 220. The opening 152 may be larger than the connector housing 220, and thus a portion of the connector head body 230 may be visible from the outside of the module housing 150.

[0077] The connector head body 230 is formed of a heterogeneous composite material. A heterogeneous composite material refers to a material comprising a heat-resistant metal material with a melting point of 1000°C or higher and a lightweight metal material that is lighter than the heat-resistant metal material. The connector head body 230 may include a first portion 230a, relatively distant from the connector housing 220 and formed of a heat-resistant metal material, and a second portion 230b, closer to the connector housing 220 and formed of a lightweight metal material. The heterogeneous composite material of the connector head body 230 may be a cladding metal. A cladding metal is a composite metal obtained by joining two or more metals with different properties under high pressure and then performing diffusion annealing to join the different metals. The cladding metal may have a layered structure between different metals and may be used as a single material.

[0078] Heat-resistant metals are metallic materials that are difficult to melt because their melting point is 1000°C or higher. For example, metals known as refractory metals (a general term for metals with melting points above 1539°C, i.e., the melting point of iron) can be heat-resistant metals. Examples of heat-resistant metals include niobium, vanadium, tantalum, titanium, zirconium, hafnium, molybdenum, and tungsten.

[0079] Heat-resistant alloys, which are based on iron, nickel, or cobalt and are used up to about 1100°C but can withstand temperatures of 1300°C or higher, can be heat-resistant metal materials. Iron-based alloys can be improved by adding chromium and nickel to stainless steel (SUS metal) or by adding other elements. Nickel-based alloys are obtained by adding chromium and cobalt to nickel. There are also nickel-molybdenum alloys known as Hastelloy.

[0080] When a flame is generated in the battery module 10, the temperature adjacent to the connector head body 230 can rise to about 600°C or higher (for at least 5 minutes), and therefore, the connector head body 230 should be able to withstand high temperature / high pressure (100 kPa). Therefore, this disclosure proposes that the connector head body 230 comprises a heat-resistant metal material with a melting point of 1000°C or higher.

[0081] In particular, it is preferred that the heat-resistant metal material faces the cell assembly 100 within the module housing 150, and the melting point of the heat-resistant metal material is 1400°C or higher.

[0082] exist Figure 4 and Figure 5 In this embodiment, in the connector head body 230, the first portion 230a of the cell assembly 100 facing the interior of the module housing 150 is formed of a heat-resistant metal material. Compared to the first portion 230a, the second portion 230b facing the exterior of the module housing 150 (i.e., the portion that contacts the interior surface of the module housing 150 in this embodiment) is formed of a lighter metal material than the first portion 230a.

[0083] Preferably, the first portion 230a is formed of stainless steel (SUS metal), and the second portion 230b is formed of aluminum-based metal. Stainless steel (SUS metal) has a melting point of 1400°C or higher, so it does not easily melt even when a flame is generated within the battery module 10. Stainless steel (SUS metal) is inexpensive compared to other heat-resistant metals. Stainless steel (SUS metal) is also easy to process, even when manufactured together with lightweight metals as a cladding metal. Because aluminum has a melting point of 660°C, it is very lightweight while offering some resistance to high-temperature-related problems generated outside the battery module 10. Aluminum is also easy to process, even when manufactured together with stainless steel (SUS metal) as a cladding metal.

[0084] According to this disclosure, the first portion 230a of the connector head body 230 remains intact even in relatively high-temperature environments. For example, even when a flame comes into direct contact with the connector head body 230, the first portion 230a will not melt and heat transfer to the connector housing 220 opposite to the module housing 150 can be prevented.

[0085] The entire connector head body 230 is not formed of a heat-resistant metal material. Instead, only the first portion 230a of the cell assembly 100 facing the interior of the module housing 150 is made of a heat-resistant metal material, while the remaining portion (i.e., the second portion 230b facing the exterior of the module housing 150) is formed of a lightweight metal material that is lighter than the first portion 230a. Therefore, heat resistance can be ensured by applying stainless steel (SUS metal) to the portion exposed to the interior of the battery module 10 and subjected to high temperatures / pressures. The portion facing the exterior of the battery module 10 is formed of a lightweight metal material such as aluminum-based metal to reduce weight.

[0086] In conventional connectors, because the portions corresponding to the connector housing 220 and the connector head body 230 are formed solely from injection-molded plastic, these portions melt during thermal runaway, thus exposing the connector to fumes and flames. When connectors are manufactured using materials with melting points higher than those of injection-molded plastic (e.g., a single metal), the connectors can become very heavy. When a heavy connector is fastened to the module housing 150, fastening devices such as bolts 240 may loosen, making it impossible to maintain an airtight seal.

[0087] In this embodiment, since a connector using a heterogeneous composite material with high heat resistance and light weight is provided, it can meet the GB standards related to thermal runaway and achieve airtightness and weight reduction.

[0088] Therefore, according to this disclosure, a battery module including a high-temperature resistant connector is provided, wherein the hermetically sealed structure of the battery module is maintained even in the event of thermal runaway and it can withstand high-temperature / high-pressure environments. Because of the use of heterogeneous composite materials, weight and cost can be reduced compared to using a single metal.

[0089] In this embodiment, the connector head body 230 and the connector housing 220 are separate components. In another embodiment, the connector housing 220 and the connector head body 230 may be a single integrally formed component. The connector head body 230 can be manufactured by fabricating a cladding metal disc comprising heat-resistant and lightweight metal materials and then machining the cladding metal disc into a connector head body 230 having a desired shape. The connector housing 220 can be integrally manufactured with the connector head body 230 by placing the connector head body 230 and the connector terminal 210 in a mold, melting and injecting plastic into the mold, and then solidifying it; this can be based on an insertion injection molding method. When the connector housing 220 is integrally manufactured with the connector head body 230, a strong bonding force can exist between the connector housing 220 and the connector head body 230 without the need for separate fastening components. Therefore, manufacturing costs can be reduced due to the reduced number of components, and manufacturing time can be reduced and a stable connection structure can be formed because the fastening process can be omitted.

[0090] Figure 6 This is a perspective view showing a connector portion separate from the battery module according to another embodiment of the present disclosure. Figure 7 This is a perspective view illustrating a sealing gasket that may be included in a battery module according to another embodiment of the present disclosure.

[0091] Reference Figure 6 and Figure 7 The battery module 10 may also include a sealing gasket 235 located between the module housing 150 and the connector head body 230 and having a melting point of 1000°C or higher.

[0092] An opening 152 may be formed in the module housing 150, and the connector head body 230 may contact the surface of the module housing 150 via a sealing gasket 235 inside the opening 152 to maintain an airtight seal. A fastening hole through which the bolt 240 passes may be formed in the connector head body 230.

[0093] When the sealing gasket 235 and connector housing 220 are coupled to connector head body 230, connector housing 220 can be exposed through opening 152 inside module housing 150, and then module housing 150 and connector head body 230 can be fastened to each other by bolts 240. Conversely, connector head body 230 can contact the surface of module housing 150 via sealing gasket 235 inside module housing 150, and bolts 240 can be fastened to the outside of module housing 150, and then connector housing 220 can be coupled to connector head body 230 from the outside of module housing 150.

[0094] The sealing gasket 235 may have a frame shape with a hollow portion whose dimensions are the same as those of the opening 152. The outer periphery of the sealing gasket 235 may conform to the outer periphery of the connector head body 230.

[0095] The gasket 235 and the connector head body 230 can be fastened together to the module housing 150 using bolts 240. Reference numeral 237 indicates a fastening hole formed in the gasket 235 to allow the bolt 240 to pass through it.

[0096] Preferably, the sealing gasket 235 is a silicone gasket. Even in the event of thermal runaway in the battery module 10, the sealing gasket 235 remains airtight and is excellent in preventing flames and gases from being exposed to the outside of the battery module 10 through the connector 200.

[0097] The opening 152 may be large enough to be secured by the connector housing 220. The opening 152 may be larger than the connector housing 220, and therefore, a portion of the connector head body 230 may be visible from the outside of the module housing 150.

[0098] The sealing gasket 235 may be a component included in the connector 200 or a component separate from the connector 200. Even if a flame is generated in the battery module including the sealing gasket 235 and causes an abnormally high temperature condition, the battery module can maximize the effect of preventing the flame from spreading to the outside of the battery module.

[0099] According to this disclosure, the connector head body 230 remains intact even in relatively high-temperature environments. The connector head body 230 will not melt even when a flame comes into direct contact with it. The sealing gasket 235 also remains intact even in relatively high-temperature environments. The sealing gasket 235 will not melt even when a flame comes into direct contact with it. The sealing gasket 235 prevents heat transfer to the connector housing 220 opposite the module housing 150.

[0100] In conventional connectors, the portions corresponding to the connector housing 220 and the connector head body 230 are formed solely from injection-molded plastic. These portions melt during thermal runaway and are therefore exposed to fumes and flames. Conventional connectors do not include sealing components, such as gaskets 235. In this disclosure, because a battery module 10 including a gasket 235 and a connector 200 having a connector head body 230 with a melting point of 1000°C or higher and high heat resistance are provided, thermal runaway-related GB standards can be met and airtightness can be maintained.

[0101] Therefore, according to this disclosure, a battery module is provided in which the hermetically sealed structure of the battery module is maintained even in the event of thermal runaway and the high temperature / high pressure environment is tolerated.

[0102] Figure 8 This is a schematic diagram illustrating a battery pack according to an embodiment of the present disclosure. Figure 9 This is a schematic diagram illustrating a vehicle according to an embodiment of the present disclosure.

[0103] Reference Figure 8 and Figure 9 The battery pack 300 according to embodiments of the present disclosure may include at least one battery module according to the present disclosure, for example, at least one battery module 10 according to an embodiment. Furthermore, the battery pack 300 may include a battery pack housing 310 capable of accommodating at least one battery module 10. In addition to the battery module 10, the battery pack 300 may also include various other components, such as relays and current sensors, which are known at the time of filing this application.

[0104] Each battery module 10 having a generally rectangular shape can be arranged in the battery pack housing 310, and each battery module 10 is connected to ensure the power required to drive the vehicle 400.

[0105] The battery pack housing 310 is a container that permanently houses the battery module 10, and is a box with a cuboid shape. The battery pack housing 310 can be positioned at a location within the vehicle 400.

[0106] Preferably, vehicle 400 can be an electric vehicle. Battery pack 300 can be used as an electrical energy source to drive vehicle 400 by providing driving force to the motor of the electric vehicle. In this case, battery pack 300 has a high nominal voltage of 100V or higher.

[0107] The battery pack 300 can be charged or discharged by a transducer according to the drive of an internal combustion engine and / or motor. The battery pack 300 can be charged via a regenerative charging device connected to the brake. The battery pack 300 can be electrically connected to the motor of the vehicle 400 via a transducer. Furthermore, the battery pack 300 can be incorporated into another device, mechanism, or device (such as an energy storage system (ESS) using secondary batteries and the vehicle itself).

[0108] Therefore, since the battery pack 300 and the apparatus, mechanism and device (such as vehicle 400) including the battery pack 300 according to the embodiments of the present disclosure include the battery module 10 described above, the battery pack 300 and the apparatus, mechanism and device (such as vehicle 400) including the battery pack 300 can have the advantages of the battery module 10.

[0109] According to the various embodiments described above, even if a flame is generated in the battery module and causes an abnormally high temperature, the flame can be prevented from spreading to the outside of the battery module. Furthermore, according to this disclosure, even if exhaust gas is generated in the battery module and causes an abnormally high pressure, an explosion of the battery module can be prevented.

[0110] For example, even when the temperature adjacent to the module housing rises to approximately 600°C or higher (for at least 5 minutes), the battery module, including the connector as proposed in this disclosure, can withstand high temperature / high pressure (100 kPa) and thus prevent heat transfer. Therefore, according to this disclosure, a battery module with improved safety, as well as a battery pack and vehicle including the battery module, can be provided.

[0111] The embodiments of this disclosure are described in more detail by describing the following experiments.

[0112] Figures 10 to 12 This is a photograph of a connector manufactured for experimental purposes. First, refer to... Figure 10 The diagram shows a connector housing 220 including connector terminals 210, a connector head body 230, and a sealing gasket 235 constituting the connector 200.

[0113] Figure 11 This photograph, taken from the connector head body 230 after assembling the connector 200 and sealing gasket 235, specifically shows the interior of the battery module housing. The first portion 230a of the connector head body 230 is formed of SUS metal. The second portion 230b of the connector head body 230 is formed of aluminum. Both portions 230a and 230b are formed of a heterogeneous composite material as the cladding metal. The cladding metal has a thickness of 6 mm, and the SUS metal portion of the cladding metal constitutes 10% of the total cladding metal thickness.

[0114] Figure 12 This photograph, taken after assembling connector 200 and sealing gasket 235, shows the exterior of the battery module housing. Sealing gasket 235 is formed of silicone resin. The thickness of sealing gasket 235 is 2 mm.

[0115] Figure 13 and Figure 14 These are photos of the test setup used to verify connector 200. This is to simulate the situation where connector 200 is mounted on the module housing, as shown... Figure 13 As shown, connector 200 is mounted on plate 150', which is made of aluminum and resembles module housing 150, via sealing gasket 235. To simulate a flame inside the module housing, a test is performed by heating with a welding torch 500 from the opposite side of plate 150'. To check the temperature of each part during the test, [further details are needed]. Figure 14 As shown, the temperature measurement lines are connected to positions 'a', 'b', and 'c' respectively. Position 'a' is close to the first part 230a, which is directly exposed to the flame. Position 'b' corresponds to the space between the connector head body 230 and the sealing gasket 235. Position 'c' corresponds to the space between the sealing gasket 235 and the plate 150'.

[0116] Figure 15 It is a graph showing the test results. Figure 15 A photograph of connector 200 taken at a specific point in time is shown as an inserted image.

[0117] The time when the flame is first generated by the welding torch 500 is set to 0 on the horizontal axis of the graph, and the temperatures at positions a, b, and c are measured over time, mapped to the vertical axis, and represented as a graph. The temperature change at position a corresponds to the temperature change at the first portion 230a, which is the part directly exposed to the flame, and as... Figure 15 As shown, the temperature is very high, around 1000°C. However, because the first part 230a blocks heat transfer, the temperature at position b, corresponding to the space between the connector head body 230 and the sealing gasket 235, drops to about 400°C. Furthermore, when the sealing gasket 235 blocks heat transfer, the temperature at position c, corresponding to the space between the sealing gasket 235 and the plate 150', remains at 200°C or lower, and rises to about 400°C after 5 minutes. Thus, because of the inclusion of the connector 200 and the sealing gasket 235, heat transfer to the outside of the module housing is prevented even if a flame is generated within the module housing.

[0118] In particular, the heat resistance effect is significant when looking at images inserted over time.

[0119] Reference Figure 15 Inserted image 1 shows that connector housing 220 begins to deform 40 seconds after being heated with soldering torch 500. Inserted image 2 is a photograph taken 1 minute and 11 seconds later, and connector housing 220 begins to burn. Next, as shown in inserted image 3, connector housing 220 separates after 30 minutes. Inserted image 4 is a photograph taken 4 minutes later, and connector housing 220 is completely burned but no flame is exposed to the outside of plate 150'.

[0120] Therefore, as proposed in this disclosure, when connector 200 is formed of a heterogeneous composite material, connector housing 220 separates after 3 minutes. However, in conventional connectors of the prior art, the connector housing separates immediately after flame exposure. This is because conventional connectors are formed only of plastic material, not a heterogeneous composite material. When connector 200 is formed of a heterogeneous composite material, the flame is not exposed to the outside. Otherwise, the connector housing separates immediately, and thus the flame is exposed to the outside within 10 minutes. The connector 200 according to this disclosure can withstand a flame of 1000°C for up to 5 minutes and has a significant effect in preventing flame exposure to the outside of the module housing.

[0121] Furthermore, when a flame is generated in the battery module, a high-pressure environment of approximately 100 kPa is created. Although the above experiment was performed with the connector 200 mounted on the board 150' and not sealed, since the connector 200 remains heat-resistant even when a flame of 1000°C is applied to it, it is reasonably expected that the connector 200 of this disclosure can withstand the high pressure caused by the flame.

[0122] While one or more embodiments of this disclosure have been described with reference to the embodiments and accompanying drawings, this disclosure is not limited thereto, and those skilled in the art will understand that various changes in form and detail may be made therein without departing from the scope of this disclosure as defined by the appended claims.

[0123] [Explanation of reference numerals in the attached figures]

[0124] 10: Battery Module

[0125] 100: Battery cell assembly

[0126] 150: Module housing

[0127] 200: Connector

[0128] 210: Connector terminal

[0129] 220: Connector housing

[0130] 230: Connector head body

[0131] 235: Sealing gasket

Claims

1. A connector, the connector comprising: Connector terminals; A connector housing surrounding the connector terminals; as well as A connector head body is attached to the connector housing, and the connector head body is formed of a heterogeneous composite material, the heterogeneous composite material comprising a first part and a second part, the first part being formed of a heat-resistant metal material with a melting point of 1000°C or higher, and the second part being formed of a lightweight metal material that is lighter than the heat-resistant metal material. The first portion includes a step configured to receive the connector housing.

2. The connector according to claim 1, wherein, The first portion is relatively far from the connector housing, and the second portion is closer to the connector housing than the first portion.

3. The connector according to claim 1, wherein, The first portion is relatively far from the connector housing and is made of stainless steel, while the second portion is closer to the connector housing than the first portion and is made of an aluminum-based metal material.

4. The connector according to claim 1, wherein, The heterogeneous composite material is a cladding metal.

5. A battery module, the battery module comprising: The battery cell assembly includes at least one battery cell; A module housing, in which the battery cell assembly is housed; as well as Connector, which is mounted on the module housing. The connector includes: Connector terminals for electrical connection to the battery cell; Connector housing, the connector housing surrounding the connector terminals; and A connector head body is attached to the connector housing and mounted on the module housing such that at least a portion of the connector head body is inserted into the module housing. The connector head body is formed of a heterogeneous composite material, which includes a first part and a second part. The first part is formed of a heat-resistant metal material with a melting point of 1000°C or higher, and the second part is formed of a lightweight metal material that is lighter than the heat-resistant metal material. The first portion includes a step configured to receive the connector housing.

6. The battery module according to claim 5, wherein, The connector is a sensing connector used to monitor the voltage of the battery cell.

7. The battery module according to claim 5, wherein, The first portion faces the battery cell assembly inside the module housing, and the second portion faces the outside of the module housing.

8. The battery module according to claim 5, wherein, The first portion faces the cell assembly inside the module housing and is made of stainless steel, while the second portion faces the outside of the module housing and is made of an aluminum-based metal material.

9. The battery module according to claim 5, wherein, In the connector head body, the heat-resistant metal material faces the battery cell assembly inside the module housing, and the melting point of the heat-resistant metal material is 1400°C or higher.

10. The battery module according to claim 5, wherein, The heterogeneous composite material is a cladding metal.

11. The battery module according to claim 5, wherein, An opening is formed in the module housing, and the connector head body contacts the surface of the module housing within the opening, and a fastening bolt is used to keep the opening airtight.

12. The battery module according to claim 11, wherein, The first portion faces the battery cell assembly inside the module housing, and the second portion faces the outside of the module housing.

13. The battery module according to claim 5, wherein, The connector housing is connected to the connector head body by press fitting or hook fastening.

14. The battery module according to claim 5, wherein, The connector housing and the connector head body are a single, integrally formed product.

15. The battery module according to claim 5, further comprising a sealing gasket located between the module housing and the connector head body and having a melting point of 1000°C or higher.

16. The battery module according to claim 15, wherein, An opening is formed in the module housing, and the connector head body contacts the surface of the module housing within the opening via the sealing gasket to maintain the opening airtight.

17. The battery module according to claim 16, wherein, The sealing gasket has a frame shape, and the frame shape has a hollow portion of the same size as the opening.

18. The battery module according to claim 15, wherein, The sealing gasket and the connector head body are fastened to the module housing using bolts.

19. The battery module according to claim 15, wherein, The sealing gasket is a silicone resin gasket.

20. A battery pack, the battery pack comprising: At least one battery module according to any one of claims 5 to 19; as well as A battery pack housing for packaging at least one battery module.

21. A vehicle comprising at least one battery pack according to claim 20.

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