Battery module and battery pack and vehicle including same

Abstract

The present invention relates to a battery module, comprising: a cell stack, the cell stack comprising a plurality of battery cells; the module shell is used for accommodating the battery cell stack; and a protective layer disposed on an outer surface of the module case so as to prevent heat conduction and heat radiation to the outside of the module case.

Description

Technical Field

[0001] The present disclosure relates to a battery module, and a battery pack and a vehicle including the battery module.

[0002] This application claims priority to Korean Patent Application No. 10-2023-0091921 filed in Korea on Jul. 14, 2023, the disclosure of which is incorporated herein by reference. Background Art

[0003] Secondary batteries are often used not only in portable devices, but also in electric vehicles (EV) or hybrid electric vehicles (HEV) powered by power supplies due to their easy application to different types of products and electrical properties such as high energy density. Secondary batteries significantly reduce the use of fossil fuels, and in addition to their main advantages, they do not produce byproducts due to the use of energy. From this perspective, secondary batteries are regarded as a more environmentally friendly and energy-saving new energy source.

[0004] Types of secondary batteries widely used now include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, etc. When a higher output voltage is required, a plurality of battery cells can be connected in series to form a battery module or a battery pack. In addition, a battery module or a battery pack can be formed by connecting a plurality of battery cells in parallel to increase the charge / discharge capacity. Therefore, the number of battery cells included in the battery module or battery pack can be set differently according to the required output voltage or charge / discharge capacity.

[0005] Meanwhile, because battery cells involve chemical reactions during charging and discharging, performance may be degraded when used in an environment above the optimal temperature, and fire or explosion may occur unexpectedly when heat cannot be controlled to the optimal temperature. In addition, the battery module has a structure in which battery cells are densely packed in a module housing. Therefore, when a thermal event occurs in any one battery cell, high-temperature gas and flames may spread to adjacent battery cells, resulting in very dangerous situations such as explosion propagation.

[0006] In addition, because the module case is made of a metal having a relatively high thermal conductivity (eg, aluminum), when a thermal event occurs in a battery cell, the heat is likely to be conducted to the outside or inside of the battery module, thereby causing thermal runaway.

[0007] Therefore, it is necessary to develop a structure for preventing heat from accumulating in a battery module due to high-temperature gas or flame generated from the battery module in the event of thermal runaway in the battery module, thereby suppressing and delaying heat propagation in the battery module.

[0008] Furthermore, in a battery pack including densely packed battery modules, it is necessary to develop a structure for minimizing heat conduction and heat radiation to other adjacent battery modules when a thermal event occurs in any battery module, thereby suppressing and delaying heat propagation between battery modules. Summary of the invention

[0009] Technical issues

[0010] The present disclosure is directed to providing a battery module capable of preventing heat from accumulating in the battery module due to gas or flame generated from the battery module when thermal runaway occurs in the battery module, thereby effectively preventing or delaying the thermal runaway from propagating in the battery module.

[0011] The present disclosure also relates to providing a battery module that can minimize heat conduction and heat radiation to other adjacent battery modules when thermal runaway occurs in the battery module, thereby effectively preventing or delaying the propagation of thermal runaway between battery modules.

[0012] Therefore, the present disclosure is also directed to providing a battery module having improved safety and reliability.

[0013] In addition, the present disclosure also relates to providing a battery pack and a vehicle including the battery module.

[0014] However, the technical problems to be solved by the present disclosure are not limited to the above-mentioned problems, and those skilled in the art will clearly understand these and other problems from the following description.

[0015] Technical Solution

[0016] In order to solve the above problems, the present disclosure provides a battery module, comprising: a cell stack, the cell stack comprising a plurality of battery cells; a module shell, the module shell being configured to accommodate the cell stack; and a protective layer, the protective layer being arranged on an outer surface of the module shell and being configured to prevent heat conduction and heat radiation to the outside of the module shell.

[0017] The module case may have at least one vent hole in an upper surface through which gas from the battery cell may be exhausted, and the protective layer may exist on the upper surface of the module case and on an inner peripheral surface of the vent hole.

[0018] The exhaust hole may include a plurality of exhaust holes, and the protective layer may exist separately for each of the plurality of exhaust holes.

[0019] The protection layer may be present on all surfaces including the upper surface of the module case.

[0020] The protection layer may be made of a material including at least one of polyurethane or silicone.

[0021] The protective layer may be a coating layer of UL 94V-0 or higher.

[0022] The protective layer may be a foam layer conformally coated along the outer surface of the module housing.

[0023] The thickness of the protection layer may be greater than or equal to 5% and less than or equal to 50% of the thickness of the module case.

[0024] The battery module may further include a top cover attached to an upper surface of the module case by an adhesive member.

[0025] The top cover may be attached to the protective layer by means of the adhesive member.

[0026] The battery module may further include a primer layer disposed between the protective layer and the adhesive member to improve coupling strength between the module case and the top cover.

[0027] The module case may include: a U-shaped frame having an open upper surface, an open front surface, and an open rear surface and configured to accommodate the battery cell stack; and a top plate covering the open upper surface of the U-shaped frame.

[0028] Alternatively, the module case may include a single frame having an open front surface and an open rear surface and configured to accommodate the battery cell stack.

[0029] In addition, the present disclosure provides a battery pack including the battery module according to the present disclosure.

[0030] The battery pack may further include: a pack case accommodating the battery module and having a cooling member on a bottom surface, and the protection layer may exist on the both side surfaces and the upper surface of the module case.

[0031] Furthermore, the present disclosure provides a vehicle including the battery pack according to the present disclosure.

[0032] Beneficial Effects

[0033] According to one aspect of the present disclosure, when thermal runaway occurs in a battery module, heat accumulation in the battery module due to gas or flame generated from the battery module can be prevented, thereby effectively preventing or delaying the propagation of thermal runaway in the battery module. Therefore, the safety and reliability of the battery module can be ensured.

[0034] In addition, according to another aspect of the present disclosure, in the event of thermal runaway occurring in a battery module, heat conduction and heat radiation to other adjacent battery modules can be minimized, thereby effectively preventing or delaying the propagation of thermal runaway between battery modules.

[0035] In addition, according to another aspect of the present disclosure, when the top cover is attached to the outside of the battery module, the adhesive strength of the adhesive member for bonding the top cover and the battery module may be improved.

[0036] Therefore, according to another aspect of the present disclosure, it is possible to prevent or delay an event such as a fire or explosion caused by thermal runaway in a battery pack including a battery module or a device in which the battery module and the battery pack are mounted.

[0037] Furthermore, the present disclosure may have many other effects, and these effects will be described in each embodiment, or corresponding descriptions on effects that can be easily inferred by those skilled in the art will be omitted. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The accompanying drawings illustrate exemplary embodiments of the present disclosure and, together with the following detailed description, serve to provide a better understanding of the technical aspects of the present disclosure, and thus the present disclosure should not be construed as being limited to the accompanying drawings.

[0039] Figure 1 is an overall perspective view of a battery module according to an embodiment of the present disclosure.

[0040] Figure 2 is an exploded perspective view of a battery module according to an embodiment of the present disclosure.

[0041] Figure 3 is a cross-sectional view of a battery module according to an embodiment of the present disclosure.

[0042] Figure 4 yes Figure 3 Magnified view of segment A in FIG.

[0043] Figure 5 is an exploded perspective view of a battery module according to another embodiment of the present disclosure.

[0044] Figure 6 is a cross-sectional view of a battery module according to another embodiment of the present disclosure.

[0045] Figure 7 yes Figure 6 Magnified view of segment B in FIG.

[0046] Figure 8 is an exploded perspective view of a battery module according to yet another embodiment of the present disclosure.

[0047] Fig. 9is a cross-sectional view of a battery module according to still another embodiment of the present disclosure.

[0048] Fig.10 is a cross-sectional view of a battery module according to still another embodiment of the present disclosure.

[0049] Fig.11 is a schematic perspective view of a battery pack including a battery module according to an embodiment of the present disclosure.

[0050] Fig.12 is a schematic perspective view of a vehicle including a battery pack according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0051] Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Before the description, it should be understood that the terms or words used in the specification and the appended claims should not be interpreted as limited to the general meaning and dictionary meaning, but are interpreted based on the principle of allowing the inventor to appropriately define the terms for the best interpretation, based on the meaning and concept corresponding to the technical aspects of the present disclosure.

[0052] Therefore, the embodiments described herein and the illustrations shown in the accompanying drawings are exemplary embodiments of the present disclosure, which are used to describe the technical aspects of the present disclosure and are not intended to be limiting, and it should be understood that various other equivalents and modifications may be made thereto when the present application is filed.

[0053] In addition, the present disclosure may include many different embodiments. In order to avoid redundancy, the description of substantially the same or similar elements in each embodiment is omitted, and the differences will be described.

[0054] Terms indicating directions, such as up, down, left, right, front, and rear, are used for convenience of description, but it is obvious to those skilled in the art that these terms may vary according to the positions of the elements or observers.

[0055] For example, in an embodiment of the present disclosure, the X-axis direction shown in the accompanying drawings may refer to the left-right direction, the Y-axis direction may refer to the front-back direction perpendicular to the X-axis direction on the horizontal surface (XY plane), and the Z-axis direction may refer to the top and bottom direction (vertical direction) perpendicular to the X-axis direction and the Y-axis direction.

[0056] Figure 1 is a complete three-dimensional diagram of a battery module according to an embodiment of the present disclosure, Figure 2 is an exploded perspective view of a battery module according to an embodiment of the present disclosure. Figure 3 is a cross-sectional view of a battery module according to an embodiment of the present disclosure, Figure 4 yes Figure 3 Magnified view of segment A in FIG.

[0057] refer to Figures 1 to 4 , a battery module 10 according to an embodiment of the present disclosure includes a battery cell stack 100 , a module case 200 , and a protective layer 300 .

[0058] The cell stack 100 may include a battery cell 110. The battery cell 110 may include a plurality of battery cells.

[0059] The plurality of battery cells 110 may be, for example, pouch-type secondary batteries. Each of the plurality of battery cells 110 may have an electrode lead 112. Specifically, the plurality of battery cells 110 may include: an electrode assembly; a cell housing 111 accommodating the electrode assembly; and an electrode lead 112 connected to the electrode assembly and extending in an outward direction of the cell housing 111 to serve as an electrode terminal. The cell housing 111 may accommodate the electrode assembly in an accommodating portion, and the edge around the accommodating portion may form a sealing portion by heat welding.

[0060] The electrode lead 112 may include a pair of electrode leads, and the pair of electrode leads 112 may extend from both ends of the battery cell 110, i.e., extend in the length direction (±Y direction). In this case, the pair of electrode leads 112 may be a positive electrode lead or a negative electrode lead. If desired, the battery cell 110 may have two electrode leads 112 located only at one end in the Y-axis direction (e.g., at one end in the +Y-axis direction).

[0061] like Figure 2 As shown in , a plurality of battery cells 110 may be arranged side by side in a standing position in a vertical direction (Z-axis direction) along the left-right direction (X-axis direction). In this case, each battery cell 110 may have a sealing portion facing the front-back direction (Y-axis direction) and the top-bottom direction (Z-axis direction) and a receiving portion facing the left-right direction (X-axis direction).

[0062] The present disclosure is not limited to a specific type or shape of battery cells 110, and various battery cells 110 known at the time of filing this application may be used to form the battery cell stack 100 of the present disclosure. In this embodiment, as shown in the drawings, the battery cell 110 is a pouch-type battery cell having high energy density and easy to stack, but a cylindrical or prismatic secondary battery may be used as the battery cell 110.

[0063] The battery cell stack 100 may further include a barrier member 120. The barrier member 120 may be disposed between the battery cells 110. In particular, a plurality of barrier members 120 may be included in one battery cell stack 100. The barrier member 120 may be disposed in each or a plurality of battery cells 110. In this embodiment, the barrier member 120 may be disposed in every two or more battery cells 110. According to the above exemplary configuration of the present disclosure, since the battery cells 110 are separated or separated by means of the barrier member 120, gas or flame may be prevented from spreading across the barrier member 120 to another adjacent barrier member 120.

[0064] The barrier member 120 may be made of a material having high heat resistance and / or fire resistance (e.g., silicone or aerogel). According to the above exemplary configuration of the present disclosure, when expansion occurs in the battery cell 110, the barrier member 120 may compress the battery cell 110, thereby improving the structural rigidity of the battery cell 110.

[0065] At the same time, reference Figure 2 The battery module 10 of the present disclosure may further include a busbar frame assembly 700. The busbar frame assembly 700 may be disposed in the module housing 200 and configured to cover at least one side of the battery cell stack 100. Figure 2 As shown in , the bus bar frame assembly 700 may be coupled to the front and rear sides of the cell stack 100 .

[0066] The busbar frame assembly 700 may include a busbar frame 710 and a plurality of busbars 720. The busbar frame 710 may be substantially coupled to the front and rear sides of the battery cell stack 100. The busbar frame 710 may have a slit through which the electrode lead 112 of the battery cell 110 extends in the +Y or -Y axis direction. In addition, the busbar frame 710 may be formed of an electrically insulating material (e.g., plastic) and may have an outer surface to which the busbar 720 is attached.

[0067] In addition, the bus bar frame 710 may be coupled to the front side or the rear side of the cell stack 100 by interference fitting.

[0068] Meanwhile, the plurality of bus bars 720 are means for connecting the battery cells 110 in series and / or in parallel, and may be formed of a rod-shaped metal (e.g., copper, aluminum, nickel). The electrode leads 112 of the battery cells 110 may extend through the slits of the bus bar frame 710 in the outward direction of the bus bar frame 710, and the extended portions may be attached to the surface of the bus bar 720 by welding. At the front and rear sides of the cell stack 100, when the electrode leads 112 of each battery cell 110 and the bus bar 720 are welded in a predetermined pattern, the battery cells 110 may be connected in series and / or in parallel.

[0069] At the same time, reference Figures 1 to 4 , the battery module 10 according to an embodiment of the present disclosure may include a module case 200. The module case 200 may be configured to accommodate the battery cell stack 100. Specifically, the module case 200 may have an internal space and be configured to accommodate the battery cell stack 100 and the bus bar frame assembly 700 in the internal space.

[0070] Meanwhile, the module housing 200 may include a housing body 210a or 210b. Figures 1 to 4 As shown in , the shell body 210a or 210b may be a U-shaped frame 210a. The U-shaped frame 210a may cover the two side surfaces and the lower surface of the battery cell stack 100. The U-shaped frame 210a may include a left side plate and a right side plate covering the two side surfaces of the battery cell stack 100 and a lower plate covering the lower surface of the battery cell stack 100. In addition, the left side plate, the right side plate and the lower plate may be formed integrally. In this case, the U-shaped frame 210a may have an open upper surface, an open front surface, and an open rear surface. The U-shaped frame 210a may be made of a metal having rigidity and heat resistance to physically or chemically protect the received battery cell 110.

[0071] When the housing body 210a or 210b is a U-shaped frame 210a, the module housing 200 may further include a top plate 220. The top plate 220 may form the upper surface of the U-shaped frame 210a. The top plate 220 may be coupled to the open upper surface of the U-shaped frame 210a. The top plate 220 may be coupled to the U-shaped frame 210a by welding. In this case, the top plate 220 and the U-shaped frame 210a may be coupled to a rectangular tube shape having an open front surface and an open rear surface.

[0072] In addition, the housing body 210a or 210b may allow the battery cell 110 to be inserted into the housing body 210a or 210b in one direction. For example, the battery cell 110 may be inserted into the housing body 210a or 210b in the front-to-back direction (Y-axis direction). When the housing body 210a or 210b is a U-shaped frame 210a, the U-shaped frame 210a may be configured to allow the battery cell 110 to be inserted therein by a sliding method.

[0073] Figure 5 is an exploded perspective view of a battery module according to another embodiment of the present disclosure, Figure 6 is a cross-sectional view of a battery module according to another embodiment of the present disclosure, and Figure 7 yes Figure 6 Magnified view of segment B in FIG.

[0074] Alternatively, if Figures 5 to 7As shown in , the housing body 210a or 210b may be a single frame 210b. The single frame 210b may be formed in a rectangular tube shape having an upper surface, a lower surface, a left side surface, and a right side surface, and having an open front surface and an open rear surface. In addition, the upper surface, the lower surface, the left side surface, and the right side surface may be formed integrally. The single frame 210b may be made of a metal having rigidity and heat resistance to physically or chemically protect the received battery cell 110.

[0075] When the housing body 210a or 210b is a single frame 210b, the battery cell stack 100 can be assembled with the busbar frame assembly 700 and inserted into the single frame 210b by interference fit. In this case, for the interference fit connection, there is almost no gap between the upper and lower surfaces of the single frame 210b and between the battery cells 110, and there is almost no gap between the two side surfaces of the single frame 210b and the two sides of the battery cell 110.

[0076] In addition, the module housing 200 can be formed in many different shapes. For example, the module housing 200 may include: a box-shaped lower housing having an open upper end; and an upper cover that closes the open upper end of the lower housing. In this case, the lower housing may be in the form of an integrated left and right side plates covering both side surfaces of the battery cell stack 100 and a front plate and a rear plate covering the front and rear surfaces of the battery cell stack 100.

[0077] At the same time, reference Figure 2 and Figure 5 , the module housing 200 may include an end plate 230 at an open front surface and an open rear surface of the housing body 210a or 210b. The end plate 230 may be coupled to the housing body 210a or 210b by welding. Although not shown for convenience, the end plate 230 may be made of, for example, an insulating material on the inside and a metal material on the outside. In addition, the end plate 230 may have a hole or slit at a specific area for exposing components that need to be exposed, such as a connector or the positive and negative terminals of the battery module 10.

[0078] At the same time, if Figures 1 to 7 As shown in FIG. 1 , the module housing 200 may have a vent hole H1. The vent hole H1 may be configured to release exhaust gas from the battery cell 110 to the outside of the module housing 200. The vent hole H1 may be formed on one side of the module housing 200 to achieve directional exhaust in one direction. For example, the vent hole H1 may be formed in the upper surface of the module housing 200.

[0079] For example, Figures 1 to 4As shown in , when the housing body 210 is a U-shaped frame 210a, the exhaust hole H1 may be formed in the top plate 220 so that directional exhaust in the upward direction of the battery module 10 can be achieved by means of the exhaust hole H1. The exhaust hole H1 may include a plurality of exhaust holes, and the plurality of exhaust holes H1 may be arranged at regular intervals along the horizontal direction (X-axis, Y-axis direction).

[0080] As described above, the exhaust hole H1 formed in the upper surface of the module housing 200 may be configured to release gas or flame generated from the battery module 10 to the outside of the battery module 10 in the event of thermal runaway in the battery module 10. The remaining area of ​​the module housing 200 except for the exhaust hole H1 may be covered, and the gas or flame may be discharged directly toward the exhaust hole H1.

[0081] According to the above exemplary configuration of the present disclosure, when a thermal event occurs in a specific position of the battery cell 110, gas or flame generated from the battery cell 110 can be discharged outside the battery module 10 via a specific exhaust hole H1 formed on the top of the battery cell 110, thereby achieving smooth exhaust.

[0082] refer to Figures 1 to 7 The battery module 10 according to the embodiment of the present disclosure may further include a protective layer 300 . The protective layer 300 may exist on the outer surface of the module case 200 .

[0083] The module housing 200 may cover the two side surfaces, the upper surface, and the lower surface of the battery cell stack 100 by means of a U-shaped frame 210a and a top plate 220, or cover the two side surfaces, the upper surface, and the lower surface of the battery cell stack 100 by means of a single frame 210b. In addition, the module housing 200 may cover the front surface and the rear surface of the battery cell stack 100 by means of an end plate 230. As described above, the module housing 200 may cover a total of six surfaces of the battery cell stack 100, namely, two side surfaces, an upper surface, a lower surface, a front surface, and a rear surface. The protective layer 300 may be present on at least one of the six surfaces of the module housing 200. The protective layer 300 may be present on the outer surface of the module housing 200.

[0084] The protective layer 300 may be configured to prevent heat conduction and heat radiation to the outside of the module housing 200. To this end, the protective layer 300 may be made of a material having a lower thermal conductivity than the module housing 200. For example, the protective layer 300 may include at least one material of polyurethane or silicone. In addition, the protective layer 300 may be a coating layer having a UL 94V-0 or higher grade and may have flame retardancy. The protective layer 300 may have fire resistance.

[0085] The module housing 200 may be made of a metal having high thermal conductivity, such as aluminum. Because metal has thermal conductivity, the heat of high temperature gas or flame may diffuse to adjacent battery modules. However, according to the above exemplary configuration of the present disclosure, since the protective layer 300 is present on the outer surface of the module housing 200, heat conduction and heat radiation to the outside of the module housing 200 may be prevented. Therefore, according to the above exemplary configuration of the present disclosure, the propagation of thermal runaway between battery modules may be effectively prevented or delayed, thereby ensuring the safety and reliability of the battery module.

[0086] In addition, according to the above exemplary configuration of the present disclosure, it is possible to prevent heat from accumulating in the battery module due to gas or flame generated from the battery module when thermal runaway occurs in the battery module, thereby effectively preventing or delaying the propagation of thermal runaway in the battery module.

[0087] Specifically, refer to Figure 3 , Figure 4 , Figure 6 and Figure 7 , the protective layer 300 may exist on the upper surface of the module housing 200 and the inner peripheral surface of the exhaust hole H1. For example, the protective layer 300 may exist on the upper surface of the top plate 220 or the single frame 210b. In addition, the protective layer 300 may exist separately for each of the plurality of exhaust holes H1.

[0088] Heat is likely to accumulate at the upper surface of the module housing 200 having the exhaust hole H1, or the high-temperature gas or flame exhausted through the exhaust hole H1 is likely to cause heat conduction to the outside of the module housing 200. However, according to the above-described exemplary configuration of the present disclosure, since the protective layer 300 having a fire-resistant property exists not only on the upper surface of the module housing 200 having the exhaust hole H1 but also on the inner peripheral surface of the exhaust hole H1, heat conduction can be prevented even when a portion of the metal of the module housing 200 is exposed. Therefore, according to the above-described exemplary configuration of the present disclosure, it is possible to prevent the high-temperature gas or flame exhausted through the exhaust hole H1 from causing heat conduction to the adjacent battery cell 110 or the adjacent exhaust hole H1.

[0089] In addition, refer to Figure 3 , Figure 4 , Figure 6 and Figure 7 , the protective layer 300 may exist on all surfaces including the upper surface of the module housing 200. For example, the protective layer 300 may also exist on the bottom surface of the module housing 200. According to the above exemplary configuration of the present disclosure, regardless of the placement structure or position of the battery module 10, the battery pack including the battery module 10 can prevent heat propagation between the battery modules 10, thereby improving the heat propagation performance of the battery pack.

[0090] Meanwhile, the protective layer 300 may be a coating layer formed by directly foaming on the outer surface of the module housing 200. According to the above exemplary configuration of the present disclosure, it is easier to cover the inner peripheral surface of the exhaust hole H1 than to attach a sheet-like fire-resistant member separately provided in the module housing 200. In addition, a process of separately manufacturing a fire-resistant member of a size suitable for the outer surface of the module housing 200 may be omitted, thereby reducing the cost and time of manufacturing the battery module.

[0091] The protective layer 300 may be a conformal coating layer along the outer surface of the module housing 200. In particular, the protective layer 300 may be a conformal coated foam layer. Here, conformal coating refers to a thin coating for preventing corrosion. The conformal coating material may include polyurethane or silicone as described above. These materials can easily form a coating layer on the outer surface of the module housing 200 of the assembled battery module 10 by a foam coating method.

[0092] In addition, using the conformal coating method, the protective layer 300 with uniform thickness can be coated along the curve of the outer surface of the module case 200. For example, the thickness of the protective layer 300 at the upper surface of the module case 200 and the thickness of the protective layer 300 at the inner peripheral surface of the exhaust hole H1 can be uniform.

[0093] According to the above exemplary configuration of the present disclosure, the drying time can be reduced, thereby shortening the manufacturing time, and the coating layer can be easily inspected, thereby improving productivity. In addition, the thickness can be uniformly coated along the curve of the outer surface of the module housing 200, thereby preventing even a portion of the metal of the module housing 200 from being directly exposed, and maintaining the heat conduction and heat radiation prevention effect over the entire area of ​​the module housing 200.

[0094] refer to Figure 4 and Figure 7 , the thickness t of the protective layer 300 may be 5% or more and 50% or less of the thickness T of the module housing 200. For example, when the thickness T of the wall of the top plate 220 and the housing body 210 is 2 mm, the thickness t of the protective layer 300 may be 0.1 mm or more and 1.0 mm or less. According to the above exemplary configuration of the present disclosure, even if foam appears in the protective layer 300 on the outer surface of the module housing 200, the height of the battery module 10 will not increase significantly, and the volume of the battery module 10 will not increase, and thus the energy density will not be significantly affected.

[0095] Figure 8 is an exploded perspective view of a battery module according to another embodiment of the present disclosure, Fig. 9 is a cross-sectional view of a battery module according to yet another embodiment of the present disclosure, and Fig.10 is a cross-sectional view of a battery module according to still another embodiment of the present disclosure.

[0096] At the same time, reference Figures 8 to 10 , the battery module 10 according to the embodiment of the present disclosure may further include a top cover 400 .

[0097] The top cover 400 may be made of a material having high heat resistance and / or fire resistance (e.g., mica), or may be formed of a mat including a fire resistant barrier (FRB) and silicone. The FRB may include an inorganic material that is easily converted and may be made of a material having very high flame retardancy and combustibility.

[0098] Therefore, when high temperature heat is generated, shrinkage can be prevented and shape stability can be maintained, thereby stably blocking high temperature gas or flame generated by the battery cell 110. In addition, with the top cover 400, when a thermal event occurs in the battery module 10, heat from high temperature gas or flame can be prevented from being transferred to the outside.

[0099] The top cover 400 may be coupled to one side of the module case 200. The top cover 400 may be configured to cover an upper surface of the module case 200. Specifically, the top cover 400 may be coupled to an upper surface of the top plate 220 or the single frame 210b.

[0100] The top cover 400 may have a cover hole H2. The cover hole H2 may include a plurality of cover holes and may be formed to correspond to the exhaust hole H1. That is, the cover hole H2 may be formed in the same shape and size as the exhaust hole H1 at a position where the exhaust hole H1 is formed. The cover hole H2 may be separated from the module housing 200 by the pressure of the exhaust gas from the battery cell 110. Specifically, when the gas is exhausted through the exhaust hole H1 corresponding to the cover hole H2, the top cover 400 may be broken only at the cover hole H2 provided above the exhaust battery cell 110. To this end, a notch groove may be formed along the shape of the cover hole H2.

[0101] In other words, under normal circumstances, the top cover 400 can cover all the exhaust holes H1 formed in the upper surface of the module housing 200 to protect the battery cell stack 100 inside the module housing 200. However, when a thermal event that generates exhaust gas or flame occurs in any battery cell 110, at least one of the cover holes H2 of the top cover 400 can be separated from the module housing 200 to effectively force the exhaust gas or flame to be directly discharged outside the battery module 10 via the exhaust hole H1 without blocking the path. In addition, the cover hole H2 remaining in the module housing 200 can block the heat generated by the battery cell 110 as well as the high-temperature gas, flame, and sprayed material.

[0102] According to the above exemplary configuration of the present disclosure, since at least some of the cover holes H2 may be completely separated from the module case 200 , the exhaust holes H1 may be exposed to the outside of the battery module 10 , and gas or flame may be completely exhausted out of the battery module 10 .

[0103] Because the module housing 200 is made of a metal including aluminum, it may be difficult to couple the module housing 200 to the top cover 400 made of mica. Therefore, the battery module 10 according to another embodiment of the present disclosure may further include an adhesive member 500. The top cover 400 may be attached to the upper surface of the module housing 200 by means of the adhesive member 500. The adhesive member 500 may include an adhesive, a tape. The entire area of ​​the top cover 400 except the cover hole H2 may be attached to the upper surface of the module housing 200 by means of the adhesive member 500.

[0104] Specifically, refer to Fig. 9 , the protective layer 300 may be present on the upper surface of the module housing 200, and the top cover 400 may be attached to the protective layer 300. That is, the top cover 400 may be attached to the protective layer 300 by means of the adhesive member 500. Therefore, the module housing 200 / protective layer 300 / adhesive member 500 / top cover 400 may be arranged in sequence from the bottom. When the adhesive member 500 is formed on the protective layer 300, the matching performance between the protective layer 300 and the adhesive member 500 may be further improved compared to when the adhesive member 500 is directly formed on the module housing 200 made of metal.

[0105] In the event of thermal runaway in the battery module 10, the adhesive member 500 may melt due to the pressure of the gas from the battery cell 110 and / or the high temperature heat of dust or flame, resulting in low adhesive strength between the module case 200 and the top cover 400. When the exhaust pressure of the exhaust gas is applied between the module case 200 and the top cover 400 bonded with low adhesive strength, the top cover 400 may be pushed in the exhaust direction of the exhaust gas and separated from the module case 200. In this case, if the top cover 400 is kept from being separated from the module case 200 with the low adhesive strength of the adhesive member, the path of the exhaust gas or flame may be blocked, and the exhaust gas or flame may re-enter the battery module 10 via the interface having a gap between the top cover 400 and the module case 200.

[0106] In contrast, according to the above exemplary configuration of the present disclosure, when the top cover 400 is bonded to the module case 200 using the protective layer 300, the bonding strength between the protective layer 300 and the bonding member 500 can be improved, thereby preventing the top cover 400 from being separated from the module case 200 due to high-temperature gas or flame when a thermal event occurs. Therefore, the exhausted gas or flame can be prevented from entering the battery module 10 again. Therefore, the safety and reliability of the battery module 10 can be ensured.

[0107] refer to Fig.10, the battery module 10 according to another embodiment of the present disclosure may further include a primer layer 600. The primer layer 600 may be made of a specially treated material to perform a primer function. The primer layer 600 may be applied to the protective layer 300 to improve the bonding strength of the bonding member 500. That is, the primer layer 600 may be interposed between the protective layer 300 and the bonding member 500, and the module housing 200 / protective layer 300 / primer layer 600 / bonding member 500 / top cover 400 may be arranged in sequence from the bottom.

[0108] According to the above exemplary configuration of the present disclosure, the protective layer 300 may be used as a base layer for forming the primer layer 600, making it easy to form the primer layer 600. In addition, the protective layer 300 may have a high matching performance with the primer layer 600, helping to prevent the primer layer 600 from being separated and to maintain the primer layer 600. Therefore, the protective layer 300 may be subjected to special treatment to further improve the coupling strength between the module case 200 and the top cover 400.

[0109] Fig.11 is a schematic perspective view of a battery pack including a battery module according to an embodiment of the present disclosure.

[0110] refer to Fig.11 , the battery pack 1 according to an embodiment of the present disclosure may include at least one battery module 10 according to an embodiment of the present disclosure as described above. The battery pack 1 according to the present disclosure may further include: a battery pack housing 2, which houses a battery management system (BMS) for controlling the charge / discharge of at least one battery module 10; a current sensor and a fuse; and the above-mentioned components. There may be a cooling member on the bottom surface of the battery pack housing 2 to cool the battery module 10. In this case, the protective layer 300 may be formed on the two side surfaces and the upper surface of the module housing 200 except the bottom surface. Therefore, the bottom surface without the protective layer 300 can directly and quickly cool the battery module 10 through the thermal contact between the cooling member and the battery module 10, and can prevent heat conduction and heat radiation by the protective layer 300 formed on the remaining surface of the module housing 200.

[0111] Fig.12 is a schematic perspective view of a vehicle including a battery pack according to an embodiment of the present disclosure.

[0112] refer to Fig.12The vehicle 3 according to the embodiment of the present disclosure may include at least one battery pack 1 according to the embodiment of the present disclosure or at least one battery module 10 according to the embodiment of the present disclosure. The vehicle 3 according to the present disclosure may include, for example, an electric vehicle, a hybrid electric vehicle, or a plug-in hybrid electric vehicle. The vehicle 3 includes a four-wheel vehicle and a two-wheel vehicle. The vehicle 3 operates using power supplied from the battery pack 1 or the battery module 10 according to the embodiment of the present disclosure.

[0113] Although the present disclosure has been described above through a limited number of embodiments and drawings, the present disclosure is not limited thereto, and it is apparent to a person skilled in the art in the technical field to which the present disclosure relates that various modifications and changes may be made within the technical aspects of the present disclosure and the scope of the appended claims and their equivalents.

Claims

1. A battery module, comprising: A battery cell stack, the battery cell stack comprising a plurality of battery cells; A module housing configured to accommodate the battery cell stack; as well as A protective layer is disposed on an outer surface of the module housing and is configured to prevent heat conduction and heat radiation to the outside of the module housing.

2. The battery module according to claim 1, wherein: The module housing has at least one vent hole in an upper surface, wherein gas from the battery cell is exhausted through the vent hole, and The protective layer exists on the upper surface of the module housing and on the inner peripheral surface of the exhaust hole.

3. The battery module according to claim 2, wherein: The exhaust hole comprises a plurality of exhaust holes, and The protective layer exists separately for each of the plurality of exhaust holes.

4. The battery module according to claim 2, wherein: The protective layer exists on all surfaces including the upper surface of the module housing.

5. The battery module according to claim 1, wherein: The protective layer is made of a material including at least one of polyurethane or silicone.

6. The battery module according to claim 1, wherein: The protective layer is a coating layer of UL 94V-0 or higher.

7. The battery module according to claim 1, wherein: The protective layer is a foam layer conformally coated along the outer surface of the module housing.

8. The battery module according to claim 1, wherein: The thickness of the protection layer is greater than or equal to 5% and less than or equal to 50% of the thickness of the module case.

9. The battery module according to claim 1, further comprising: A top cover is attached to an upper surface of the module case by an adhesive member.

10. The battery module according to claim 9, wherein: The top cover is attached to the protective layer by means of the adhesive member.

11. The battery module according to claim 10, further comprising: A primer layer is disposed between the protective layer and the adhesive member to improve coupling strength between the module case and the top cover.

12. The battery module according to claim 1, wherein: The module housing comprises: a U-shaped frame having an open upper surface, an open front surface, and an open rear surface and configured to accommodate the battery cell stack; and A top plate covers the open upper surface of the U-shaped frame.

13. The battery module according to claim 1, wherein: The module case includes a single frame having an open front surface and an open rear surface and configured to accommodate the battery cell stack. 14 . A battery pack comprising the battery module according to claim 1 .

15. The battery pack according to claim 14, further comprising: a battery pack case accommodating the battery module and having a cooling member on a bottom surface, Wherein, the protective layer exists on both side surfaces and the upper surface of the module housing.

16. A vehicle comprising the battery pack according to claim 14.

Images