Battery module and method for manufacturing the same

Abstract

In a battery module according to one embodiment of the present invention, performance degradation due to an electrical phenomenon is prevented by providing a larger insulation distance between a cell assembly and a frame by means of structural characteristics of an insulation portion, and prevents damage to the cell assembly due to spatter occurring during the process of welding the frame, thereby improving the yield of the battery module.

Description

Technical Field

[0001] This application claims the benefit of priority to Korean Patent Application No. 10-2022-0065688, filed on May 27, 2022, and Korean Patent Application No. 10-2023-0062576, filed on May 15, 2023, which are hereby incorporated by reference in their entirety.

[0002] The present invention relates to a battery module and a method for manufacturing the battery module. Background Art

[0003] Generally, secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, lithium-ion batteries, and lithium-ion polymer batteries. Such secondary batteries are being used in small products such as digital cameras, P-DVDs, MP3Ps, mobile phones, PDAs, portable game devices, power tools, electric bicycles, and large products requiring high power such as electric vehicles and hybrid vehicles, power storage devices for storing surplus power or renewable energy, and backup power storage devices.

[0004] Generally, in order to manufacture a secondary battery, first, an electrode active material slurry is applied to a positive electrode current collector and a negative electrode current collector to manufacture a positive electrode and a negative electrode. Then, these electrodes are stacked on both sides of a separator to form an electrode assembly. In addition, the electrode assembly is housed in a battery case, and then after an electrolyte is injected therein, the battery case is sealed.

[0005] A cell assembly can be manufactured by accommodating a plurality of electrode assemblies in a pack, and a battery module can be manufactured by accommodating the cell assembly in a frame. When the cell assembly is disposed inside the frame, the battery performance is degraded due to electrical phenomena between the frame and the cell assembly. In order to prevent this phenomenon, a method of ensuring the insulation distance between the frame and the cell assembly by attaching an insulating sheet to the inner surface of the frame is utilized. Therefore, in the process of manufacturing the battery module, it is necessary to design the arrangement and structure of the insulating sheet, thereby more effectively ensuring the insulation distance between the frame and the cell assembly.

[0006] In addition, in a welding process of the top surface of the frame in which the cell assembly is disposed, there occurs a problem that the cell assembly is damaged due to spark splash caused by welding. Therefore, a battery module having a structure to prevent damage caused by welding splash is required. Summary of the invention

[0007] Technical issues

[0008] An object of the present invention to solve the above-mentioned problems is to provide a battery module that further ensures an insulation distance between a cell assembly and a frame.

[0009] An object of the present invention to solve the above-mentioned problems is to provide a battery module that prevents a cell assembly from being damaged due to a spatter phenomenon occurring during a welding process of a frame.

[0010] Technical Solution

[0011] A battery module according to one embodiment of the present invention may include: a cell assembly; a frame in which a receiving space is defined to receive the cell assembly; and an insulating portion disposed inside a first surface which is a side surface of the frame, wherein the insulating portion may be disposed between the frame and the cell assembly and have a shape bent toward the cell assembly.

[0012] The insulating part may include: a side member connected to an inner side of the first surface; and a bending member connected to one end of the side member and having a shape bent toward the cell assembly.

[0013] The frame may include: a main body, a front surface and a rear surface of the main body arranged at the front side and the rear side in the longitudinal direction are open, and a second surface of the main body which is a surface parallel to the longitudinal direction is open, and an accommodating space is defined in the main body; an end plate, which is connected to the main body by covering the front surface and the rear surface; and a cover plate, which is connected to the main body by covering the second surface.

[0014] The first surface different from the second surface may be disposed on the body in parallel with a longitudinal direction of the body, and the bending member may protrude from the side member and be bent toward the unit assembly.

[0015] The bending member may be disposed between the unit assembly and the second surface.

[0016] The bending member may protrude from the side member in a direction perpendicular to the longitudinal direction of the body.

[0017] The unit assembly may be spaced apart from each of the front surface and the rear surface by a predetermined interval, and a portion of the side member may be disposed in a space between the unit assembly and each of the front surface and the rear surface.

[0018] In a state in which the unit assembly is seated in the accommodation space, a distance between the unit assembly and the second surface may be smaller than a distance between the unit assembly and each of the front surface and the rear surface.

[0019] The insulating part may further include a ring member connected to the other end of the bending member and having a shape bent in a direction opposite to a direction in which the bending member is bent.

[0020] A method for manufacturing a battery module according to an embodiment of the present invention, in which a cell assembly is arranged in a receiving space relative to a frame, the frame including a main body configured to define a first surface and an open second surface and a cover plate connected to the second surface to define the receiving space in the frame. In order to manufacture the battery module, the method may include the following steps: a setting process, in which an insulating part is set, the insulating part including a side member and a bending member, the side member is connected to the inner side of the first surface, the bending member protrudes from the side member and has a shape bent toward the cell assembly; a placement process, in which the cell assembly is moved through the second surface so as to be placed in the receiving space; and a welding process, in which the cover plate is covered with the second surface so as to be welded to the main body.

[0021] Beneficial Effects

[0022] According to the preferred embodiments of the present invention, the insulation distance between the cell assembly and the frame can be further ensured to prevent functional degradation due to electrical phenomena.

[0023] According to the preferred embodiments of the present invention, it is possible to prevent the cell assembly from being damaged due to the splash phenomenon occurring during the welding process of the frame to improve the yield of the battery module.

[0024] In addition, effects that are obvious to those skilled in the art can be predicted from the configuration according to the embodiment of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings in this specification illustrate preferred embodiments and functions of the present invention, so as to further understand the technical concept of the present invention together with the detailed description of the present invention. Therefore, the present invention should not be interpreted as being limited to the accompanying drawings.

[0026] Figure 1 is a perspective view of a battery module according to one embodiment.

[0027] Figure 2 is an exploded view of a frame according to one embodiment.

[0028] Figure 3 is a perspective view illustrating a state in which a unit assembly is mounted on a main body according to one embodiment.

[0029] Figure 4 is a perspective view illustrating a state in which a unit assembly according to one embodiment is mounted on a main body.

[0030] Figure 5 yes Figure 4 Magnified view of part A.

[0031] Figure 6 is an example Figure 4An enlarged view of the upper side of part A.

[0032] Figure 7 is a flowchart illustrating a method for manufacturing a battery module according to another embodiment. DETAILED DESCRIPTION

[0033] Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily implement the present invention. However, the present invention can be implemented in several different forms and is not limited or constrained by the following examples.

[0034] In order to explain the present invention clearly, the detailed description of the parts not related to the description or the related known technology that may unnecessarily obscure the gist of the present invention has been omitted, and in this specification, the parts in each figure are added with reference numerals. In this case, the same or similar reference numerals are assigned to the same or similar elements throughout the specification.

[0035] Furthermore, the terms and words used in the specification and claims should not be restrictively interpreted as ordinary meanings or dictionary-based meanings, but should be interpreted as meanings and concepts consistent with the scope of the present invention based on the principle that the inventor can appropriately define the concepts of the terms in order to best describe and explain his or her invention.

[0036] Figure 1 is a perspective view of a battery module 1 according to one embodiment.

[0037] Reference Figure 1 , the battery module 1 may include a plurality of battery cells to store electric energy and output the stored electric energy to the outside through the connection terminals. In the process of manufacturing the battery module 1 and using the process, the battery module 1 may include an insulating sheet so that current does not leak from the internal cells or the function of storing and outputting electric energy does not deteriorate. In addition, in the process of manufacturing the battery module 1 by welding, the insulating sheet may have a structure protruding in a specific direction to prevent the battery cells disposed inside the battery module 1 from being damaged by welding spatter.

[0038] The battery module 1 may include a cell assembly 10 , a frame 11 , and an insulating part 12 .

[0039] The unit assembly 10 may be a multi-battery assembly in which an electrode assembly is housed in a housing such as a package. With this structure, the unit assembly 10 may store a large amount of electric energy and output and emit the electric energy to the outside as needed.

[0040] Figure 2 is an exploded view of the frame 11 according to one embodiment.

[0041] Reference Figure 2The frame 11 may contain the cell assembly 10 by defining a containing space therein. The frame 11 may protect the cell assembly 10 from external impact and environmental influence by blocking the cell assembly 10 from an external space while containing the cell assembly 10 therein.

[0042] The frame 11 may include a body 110 , an end plate 111 , and a cover plate 112 .

[0043] The main body 110 may define a storage space. For example, the main body 110 may have a rectangular parallelepiped shape, and the front surface M3 and the rear surface M4 of the main body 110 may be arranged forward and backward in the longitudinal direction. In this case, the front surface M3 and the rear surface M4 of the main body 110 may be open to allow the storage space and the external space to communicate with each other.

[0044] In this case, the above-mentioned front surface M3 and rear surface M4 and a first surface M1 and a second surface M2 described later may refer to virtual surfaces defined by the body 110 .

[0045] In addition, the first surface M1 of the body 110 may be a surface parallel to the longitudinal direction. Unlike the front surface M3 and the rear surface M4, the first surface M1 may be a surface defined by two closed side walls of the body 110. The insulating portion 12 to be described below may be attached to the inner surface of each side wall of the body 110.

[0046] In addition, the second surface M2 of the body 110 may be a surface parallel to the longitudinal direction. The second surface M2 of the body 110 may also be open like the front surface M3 and the rear surface M4. In this case, the second surface M2 may refer to a surface different from the first surface M1. For example, the second surface M2 may be a top surface of the body 110 that is open to the upper side of the body 110.

[0047] According to this structure, when viewed from one side, the body 110 may include a U-shape. Specifically, when viewed from the front surface M3 or the rear surface M4, the body 110 may have a U-shape.

[0048] Figure 3 is a perspective view illustrating a state in which the unit assembly 10 is mounted on the main body 110 according to one embodiment, and Figure 4 1 is a perspective view illustrating a state in which the unit assembly 10 is mounted on the body 110 according to one embodiment.

[0049] Reference Figure 3 and Figure 4In the case where the cell assembly 10 is disposed above the body 110, the cell assembly 10 moves into the internal accommodation space of the body 110 through the second surface M2. When placed in the accommodation space, the cell assembly 10 may be connected to and fixed to the inner surface of the body 110.

[0050] The end plates 111 may be connected to the body 110 by covering the front surface M3 and the rear surface M4 of the body 110. In other words, the end plates 111 may be provided in pairs at the front and rear sides of the body 110 in the longitudinal direction and welded to both ends of the body 110 corresponding to the front surface M3 and the rear surface M4.

[0051] The cover plate 112 may be connected to the body 110 by covering the second surface M2 of the body 110. For example, the cover plate 112 may cover the top surface (that is, the second surface M2) of the body 110 when the cell assembly 10 is accommodated inside the body 110, thereby providing an accommodation space and an external space that are blocked from each other. In other words, the cover plate 112 may be welded to the body 110 so that the cell assembly 10 is blocked from the external space.

[0052] The insulating portion 12 may ensure an insulating distance between the frame 11 and the cell assembly 10. In other words, the insulating portion 12 may play a role in preventing electricity from passing through the space between the frame 11 and the cell assembly 10. For example, the insulating portion 12 may be disposed inside the frame 11 and be formed integrally with the frame 11. In other words, the insulating portion 12 may be disposed between the frame 11 and the cell assembly 10. That is, the insulating portion 12 may be disposed inside the first surface M1 which is a side surface of the frame 11, and the cell assembly 10 may be disposed inside the frame 11 with the insulating portion 12 between the frame 11 and the cell assembly 10. In addition, the insulating portion 12 may have a shape bent toward the cell assembly 10. The insulating portion 12 may be disposed in pairs on both sides of the frame 11.

[0053] Figure 5 yes Figure 4 A magnified view of part A, and Figure 6 is an example Figure 4 An enlarged view of the upper side of part A.

[0054] Reference Figure 5 and Figure 6 , the insulating part 12 may include a side member 120 and a bending member 121 .

[0055] The side member 120 may be connected to the inside of the first surface M1 . In other words, the side member 120 may be connected to the inner surface of the side wall of the body 110 defining the first surface M1 , and disposed along the longitudinal direction of the body 110 .

[0056] The bending member 121 may be connected to one end of the side member 120 and have a shape bent toward the cell assembly 10. For example, the bending member 121 may protrude from the side member 120 and be bent toward the cell assembly 10. Specifically, the bending member 121 may protrude from a side of the side member 120 close to the second surface M2 of the body 110. More specifically, the bending member 121 may protrude from the side member 120 so as to be perpendicular to the longitudinal direction of the body 110.

[0057] The bending member 121 may be disposed between the cell assembly 10 and the second surface M2. In other words, the bending member 121 may be disposed between the top surface of the cell assembly 10 and the second surface M2. According to this structure, the insulation distance between the cell assembly 10 and the frame 11 may be further ensured, and the bending member 121 may block welding sparks generated during welding of the cap plate 112 to the top surface of the body 110 from being sputtered toward the cell assembly 10.

[0058] The unit assembly 10 is spaced apart from the front surface M3 and the rear surface M4 by a predetermined interval, and a portion of the side member 120 may be disposed in the space between the unit assembly 10 and the front surface M3 and the rear surface M4. That is, as viewed from the upper side, the side member 120 may be disposed on each of the two surfaces of the unit assembly 10, and the side member 120 may be disposed to be longer than the unit assembly 10 in the longitudinal direction, and then connected to the front surface M3 and the rear surface M4 of the body 110.

[0059] In a state where the cell assembly 10 is placed in the accommodation space, the distance between the cell assembly 10 and the second surface M2 may be smaller than the distance between the cell assembly 10 and each of the front surface M3 and the rear surface M4. Therefore, the curved member 121 may be provided at the upper side of the side member 120, rather than the front and rear sides of the side member 120, so as to further ensure the insulation distance between the top surface of the cell assembly 10 and the second surface M2 of the body 110 (i.e., the cover plate 112).

[0060] The insulating portion 12 may further include a ring member 122 having a shape bent in a direction opposite to the direction in which the bending member 121 is bent. For example, one end of the bending member 121 may be connected to the side member 120, and the ring member 122 may be connected to the other end of the bending member 121. The ring member 122 may include a ring shape. In addition, one end of the ring member 122 may be connected to the other end of the bending member 121, and the other end of the ring member 122 may include a shape bent toward the second surface M2 of the body 110.

[0061] Therefore, according to the structural characteristics of the insulating portion 12 as described above, the insulating portion 12 can further ensure the insulation distance between the frame 11 and the unit assembly. Specifically, the insulation distance can be classified into a spatial distance and a creepage distance. Here, the spatial distance refers to the shortest distance between two conductive objects through the air, and the creepage distance refers to the shortest distance between two conductive objects along the surface of the insulating material. That is, in terms of both the spatial distance and the creepage distance, the insulation distance between the frame 11 and the unit assembly 10 can be further ensured by the structural characteristics of the bending member 121 bending toward the unit assembly 10 and the structural characteristics of the ring member 122 bending again in the opposite direction.

[0062] In addition, since the distance between the cap plate 112 and the cell assembly 10 is shorter than the distance between the end plate 111 and the cell assembly 10 , the battery module 1 can effectively utilize the insulation structure by disposing the bending member 121 and the ring member 122 between the cap plate 112 and the cell assembly 10 .

[0063] Specifically, the space distance ensured by the bending member 121 and the ring member 122 may refer to the insulation distance between the cell assembly 10 and the body 110. More specifically, the space distance may refer to the distance between the top surface of the cell assembly 10 and the inner surface of the body 110. That is, the space distance may refer to the insulation distance between the inner surface to which the insulating portion 12 of the body 110 is attached and the top surface of the cell assembly 10. In this case, due to the bending member 121 and the ring member 122, the space distance may be 2 mm to 8 mm.

[0064] When the space distance is less than 2 mm, the insulation distance between the components inside the battery module 1 may not be ensured, and thus, a short circuit may occur. In other words, if the space distance between the top surface of the cell assembly 10 and the inner surface of the body 110 is 2 mm or less due to the characteristics of the battery module 1 accommodating the cell assembly 10, current may flow between the cell assembly 10 and the body 110 to cause a short circuit phenomenon, thereby causing damage or destruction of the battery module.

[0065] In addition, when the spatial distance exceeds 8 mm, since the curved member 121 and the ring member 122 must be longer, the energy density of the battery module may be reduced or the weight of the battery module may be unnecessarily increased due to excessive occupation of the space inside the battery module. In addition, the elongated curved member 121 and the ring member 122 are inclined toward the unit assembly 10, and the insulation distance may not be properly ensured.

[0066] In addition, the creepage distance ensured by the bent member 121 and the ring member 122 may refer to a distance from the outer surface of the unit assembly 10 along the insulating portion 12 to the inner surface of the body 110. In this case, due to the bent portion 12, the creepage distance may be 8 mm to 16 mm.

[0067] When the creepage distance is less than 8 mm, the insulation distance between the components inside the battery module 1 may not be ensured, and thus, a short circuit may occur. In other words, when the distance from the top surface of the cell assembly 10 along the outer surface of the insulating portion 12 to the inner surface of the main body 110 is less than 8 mm, a short circuit may occur between the cell assembly 10 and the main body 110, and thus, current may pass between the cell assembly 10 and the main body 110. That is, the battery module may be damaged or destroyed due to the short circuit, and thus, a risk problem such as a fire may occur.

[0068] When the creepage distance exceeds 16 mm, similarly, since the curved member 121 and the ring member 122 must be longer, the energy density of the battery module may be reduced or the weight of the battery module may be unnecessarily increased due to excessive occupation of the space inside the battery module. In addition, the elongated curved member 121 and the ring member 122 are inclined toward the unit assembly 10, and the problem of not being able to properly ensure the insulation distance may occur.

[0069] However, the above numerical ranges of the space distance and the creepage distance may be only examples, and the above numerical ranges may be changed according to a design method and an application environment such as a model of a battery module and a used voltage.

[0070] Figure 7 is a flowchart illustrating a method for manufacturing the battery module 1 according to another embodiment.

[0071] Reference Figure 7 , the insulating part 12 can be connected to the inside of the frame 11, so that through the method for manufacturing the battery module 1, the cell assembly 10 accommodated therein is not damaged and the function of the battery module 1 is not deteriorated. For example, in the process of welding the frame 11, the cell assembly 10 can be prevented from being damaged due to welding spatter, thereby improving the yield of the battery module 1 and also improving the process of manufacturing the battery module 1.

[0072] In this case, as described above, the frame 11 may include the body 110, the end plate 111, and the cover plate 112. In addition, the body 110 may define the first surface M1, the second surface M2, the front surface M3, and the rear surface M4.

[0073] The method for manufacturing the battery module 1 may include a setting process ( S10 ), a mounting process ( S20 ), and a welding process ( S30 ).

[0074] In the setting process (S10), the insulating part 12 may be set inside the frame 11. In other words, as described above, the insulating part 12 may include a side member 120, a bending member 121, and a ring member 122. The side member 120 may be set on each of the two side walls of the body 110 along the longitudinal direction of the body 110, and the bending member 121 may protrude from the upper portion of the side member 120 toward the cell assembly 10.

[0075] In the placement process ( S20 ), the cell assembly 10 may be moved to be placed in the accommodation space. For example, in the case where the cell assembly 10 is disposed above the body 110 , the cell assembly 10 is moved into the internal accommodation space of the body 110 through the second surface M2 .

[0076] In the welding process ( S30 ), the cap plate 112 may be welded and connected to the body 110 by covering the second surface M2 .

[0077] According to this sequence, welding sparks generated by welding the cap plate 112 and the body 110 may fly toward the unit assembly 10 , and the insulating portion 12 may block the welding sparks from reaching the unit assembly 10 to prevent the unit assembly 10 from being damaged.

[0078] The above-disclosed subject matter is to be considered illustrative rather than restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments that fall within the true spirit and scope of the present invention.

[0079] Therefore, the embodiments of the present invention should be considered as illustrative rather than restrictive, and the technical idea of ​​the present invention is not limited to the aforementioned embodiments.

[0080] Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being included in the present invention.

[0081] [Explanation of Reference Numerals]

[0082] 1: Battery module

[0083] 10: Unit components

[0084] 11: Framework

[0085] 12: Insulation

[0086] 110: Main body

[0087] 111: End plate

[0088] 112: Cover

[0089] 120: Side member

[0090] 121: curved member 122: ring member

[0091] M1: first surface of the body M2: second surface of the body M3: front surface of the body M4: rear surface of the body S10: setting process

[0092] S20: Placement Process

[0093] S30: Welding process

Claims

1. A battery module, comprising: Unit components; a frame, wherein a receiving space is defined in the frame to receive the unit assembly; as well as an insulating portion provided inside the first surface which is a side surface of the frame, The insulating portion is disposed between the frame and the unit assembly and has a shape bent toward the unit assembly.

2. The battery module according to claim 1, wherein: The insulating portion comprises: a side member connected to an inner side of the first surface; and A bending member is connected to one end of the side member and has a shape bent toward the unit assembly.

3. The battery module according to claim 2, wherein: The framework includes: a main body, a front surface and a rear surface of the main body disposed at the front side and the rear side in the longitudinal direction of which are open, a second surface of the main body which is a surface parallel to the longitudinal direction of which is open, and in which the accommodation space is defined; an end plate connected to the main body by covering the front surface and the rear surface; and A cover plate is connected to the main body by covering the second surface.

4. The battery module according to claim 3, wherein: The first surface, which is different from the second surface, is disposed on the body in parallel with the longitudinal direction of the body, and The bending member protrudes from the side member and is bent toward the unit assembly.

5. The battery module according to claim 4, wherein: The bending member is disposed between the unit assembly and the second surface.

6. The battery module according to claim 4, wherein: The bending member protrudes from the side member in a direction perpendicular to the longitudinal direction of the body.

7. The battery module according to claim 4, wherein: The unit component is spaced apart from each of the front surface and the rear surface by a predetermined interval, and A portion of the side member is disposed in a space between the unit assembly and each of the front surface and the rear surface.

8. The battery module according to claim 4, wherein: In a state in which the unit assembly is disposed in the accommodation space, a distance between the unit assembly and the second surface is smaller than a distance between the unit assembly and each of the front surface and the rear surface.

9. The battery module according to claim 2, wherein: The insulating portion further includes a ring member connected to the other end of the bending member and having a shape bent in a direction opposite to a direction in which the bending member is bent.

10. A method for manufacturing a battery module, in which a cell assembly is arranged in a receiving space relative to a frame, the frame including a body configured to define a first surface and an open second surface and a cover plate connected to the second surface to define the receiving space in the frame, and in order to manufacture the battery module, the method includes the following steps: a setting process in which an insulating portion is set, the insulating portion including a side member connected to the inner side of the first surface and a bending member protruding from the side member and having a shape bent toward the unit assembly; a placement process in which the unit assembly is moved through the second surface so as to be placed in the accommodation space; as well as A welding process is performed in which the cover plate covering the second surface is welded to the main body.

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