Battery cell assembly and battery pack comprising same

Abstract

A battery pack includes a housing, a battery assembly, and a first cover. The housing includes an opening and a first surface opposite the opening. The battery assembly is accommodated in the housing. The first cover is coupled to the housing and covers the opening. A first side of the battery assembly is coupled to a first side of the first cover. The second side of the battery assembly is spaced apart from the first surface of the housing.

Description

Technical Field

[0001] The present disclosure relates to battery packs, and more particularly, to battery packs including one or more battery assemblies.

[0002] This application claims priority to Korean Patent Application No. 10-2023-0082724 filed in Korea on June 27, 2023, and U.S. Patent Application No. 18 / 612,931 filed in the United States on March 21, 2024, the disclosures of which are incorporated herein by reference. Background Art

[0003] Unlike primary batteries, secondary batteries can be charged or discharged multiple times. Secondary batteries are widely used as energy sources for various wireless devices (such as mobile phones, laptops, and cordless vacuum cleaners). Recently, as the manufacturing cost per unit capacity of secondary batteries has been significantly reduced due to the improvement of energy density and economies of scale, and as the cruising range of battery electric vehicles (BEVs) has increased to the same level as fuel vehicles, the main use of secondary batteries has moved from mobile devices to mobile vehicles (mobility).

[0004] As secondary batteries are used in mobile vehicles, the demand for the safety of secondary batteries is increasing. When an accident such as a fire occurs in a secondary battery used in a mobile vehicle, the accident may endanger the life of the driver, so research on technology for improving the safety of secondary batteries is essential.

[0005] When a thermal runaway event occurs inside the battery pack, the gas G and flames are directed toward the passenger compartment side, which is a risk to passenger safety. In addition, since the high-temperature gas and flames are concentrated on the top plate, which is the upper part of the battery pack, the thermal runaway event is easily transmitted to adjacent modules or battery cells.

[0006] Furthermore, since the battery assembly is closely supported on a floor panel that is a lower portion of the vehicle, the battery assembly may be damaged when an impact occurs from below the vehicle while traveling on a hard surface such as an unpaved road.

[0007] The background description provided herein is for the purpose of generally presenting the context of the present disclosure. Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to be prior art or an admission of prior art by inclusion in this section. Summary of the invention

[0008] Technical issues

[0009] An object of the present disclosure is to provide a battery pack with improved safety.

[0010] These and other purposes and advantages of the present disclosure can be understood from the following detailed description, and will become more fully apparent from the exemplary embodiments of the present disclosure. Moreover, it will be easily understood that the purposes and advantages of the present disclosure can be achieved by the means shown in the appended claims and their combinations.

[0011] Technical Solution

[0012] According to an exemplary embodiment of the present disclosure to solve the above-mentioned problems, a battery pack is provided.

[0013] In one example, a battery pack may include: a housing including an opening and a first surface opposite to the opening; a battery assembly accommodated in the housing; and a first cover coupled to the housing and covering the opening. A first side of the battery assembly may be coupled to a first side of the first cover, and a second side of the battery assembly may be spaced apart from the first surface of the housing.

[0014] In other aspects, the battery pack described herein may include one or more of the following features. The first side of the battery assembly may be attached to the first side of the first cover. The battery pack may also include a first layer between the battery assembly and the first cover. The first cover may include a cooling channel between the first side of the first cover and the second side of the first cover. The first side of the first cover may be opposite to the second side of the first cover. The battery assembly may be fastened to the first cover and / or the housing. The housing may also include a sidewall coupled to a first edge of the first surface. The housing may include a mounting portion on the sidewall. The battery assembly may be coupled to the mounting portion. The first cover may be coupled to the mounting portion. The housing may also include a venting portion. The housing may also include a support structure on the first surface. The battery assembly may be coupled to the support structure. The battery assembly may also include a cell assembly including a battery cell and a bus bar coupled to the first side of the cell assembly. The battery assembly may also include a second cover. The second cover is coupled to the second side of the cell assembly. The battery pack may also include a first layer. The first layer may include a thermal interface material (TIM). The TIM may include a thermal resin, and the first layer may be on a surface of the second cover. The battery assembly may further include: a third cover coupled to a third side of the cell assembly; and a cooling portion on at least one of the second cover or the third cover. The battery assembly may further include a second cover coupled to the second side of the cell assembly and a third cover coupled to the third side of the cell assembly. The second cover may include a first shape, and the third cover may include a second shape. The first shape and the second shape may be configured to correspond to each other for coupling. The battery assembly may include a first cell assembly and a second cell assembly. The first cell assembly may include a first bus bar, and the second cell assembly includes a second bus bar. The first cell assembly may be coupled to the second cell assembly via the first bus bar and the second bus bar. The battery assembly may further include a bus bar frame, and the bus bar frame includes a bus bar.

[0015] In another example, a vehicle may include: a battery pack and a frame. The battery pack may include: a housing including an opening and a surface opposite to the opening; a cover configured to cover the opening; and a battery assembly coupled to the cover and spaced apart from the surface. The battery pack may be housed in the frame. A passenger compartment may be disposed above at least a first portion of the battery pack. The frame may be below at least a second portion of the battery pack.

[0016] In yet another example, a battery assembly may include: a cell assembly including a battery cell; a first cover coupled to a first side of the cell assembly; a second cover coupled to a second side of the cell assembly; and a layer between the second cover and the second side of the cell assembly. The first cover may include a first cooling portion. The second cover may include a second cooling portion. The first cooling portion may include an exhaust opening. The second cooling portion may include a cooling channel.

[0017] In yet another example, a battery pack may include: a battery assembly including a plurality of battery cells; and a battery pack housing configured to accommodate the battery assembly, wherein the battery pack housing includes a top plate and a lower battery pack housing, an upper surface of the battery assembly being suspended and supported by the top plate, the lower battery pack housing including a bottom plate opposite to the top plate and connected to the top plate, and a free volume is disposed between the lower surface of the battery assembly and the bottom plate.

[0018] An upper surface of the battery assembly may be closely coupled to a lower surface of the top plate.

[0019] The battery pack may further include a thermal interface material (TIM) layer including a thermal resin between the battery assembly and the top plate, and the battery assembly may be closely coupled to and supported on a lower surface of the top plate through the TIM layer.

[0020] The top plate may have a plurality of cooling channels.

[0021] The battery assembly may be secured to the top plate and / or the lower battery pack housing.

[0022] The lower battery pack housing may have a side wall coupled to surround the bottom plate, and an assembly mounting portion configured to support a side surface of the battery assembly perpendicular to an upper surface of the battery assembly may be provided on the side wall.

[0023] The top plate may be seated on an upper surface of the component mounting portion.

[0024] The lower battery pack housing may include a vent.

[0025] A battery support may be disposed on the bottom plate, and the battery assembly may be supported by the battery support to be spaced apart from an upper surface of the bottom plate.

[0026] The battery assembly may include: a battery cell assembly including a plurality of battery cells; and a plurality of bus bars or a bus bar frame including a plurality of bus bars coupled to at least one side surface of the battery cell assembly.

[0027] The battery assembly may further include a module housing configured to house the battery cell assembly.

[0028] The battery pack may further include a TIM layer contacting at least one of an upper surface and a lower surface of the battery cell assembly on an inner surface of the module case, the TIM layer including a thermal resin.

[0029] The cooling device may be provided in at least one of an upper case in contact with an upper surface of the battery cell assembly and a lower case in contact with a lower surface of the battery cell assembly in the module case.

[0030] The battery assembly may include a first side plate coupled to a first side surface of the battery cell assembly and a second side plate coupled to a second side surface of the battery cell assembly.

[0031] The first side panel and the second side panel may have complementary structures that engage with each other.

[0032] The battery assembly may include a plurality of battery cell assemblies connected in a longitudinal direction of the battery assembly.

[0033] According to another exemplary embodiment of the present disclosure, an electric vehicle includes the above-mentioned battery pack and a vehicle body frame on which the battery pack is mounted, wherein a passenger compartment is provided at a top plate of the battery pack and the vehicle body frame is provided at a bottom plate of the battery.

[0034] Beneficial Effects

[0035] In the battery pack according to the exemplary embodiment of the present disclosure, the battery assembly is suspended and supported by a top plate positioned adjacent to the passenger compartment of the vehicle. In addition, a free volume is provided between the lower surface of the battery assembly and the bottom plate of the battery pack positioned adjacent to the bottom of the vehicle.

[0036] Therefore, even when a thermal runaway event occurs, since the high-temperature gas generated from the battery assembly moves to the free volume, the passengers in the passenger compartment can be protected.

[0037] Furthermore, even when an impact is applied to the floor of the battery pack from below the vehicle, since the battery assembly is spaced apart from the floor by the free volume, structures in the battery pack such as the battery assembly can be effectively protected.

[0038] The effects that can be obtained from the exemplary embodiments of the present disclosure are not limited to the above effects, and those skilled in the art can obtain other effects not described herein from the following description of the exemplary embodiments of the present disclosure. That is, the unexpected effects achieved according to the exemplary embodiments of the present disclosure can be designed by those skilled in the art through the exemplary embodiments of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The accompanying drawings illustrate preferred embodiments of the present disclosure and together with the foregoing disclosure are used to provide a further understanding of the technical features of the present disclosure, and therefore, the present disclosure is not interpreted as being limited to the accompanying drawings.

[0040] Figure 1 and Figure 2 is a cross-sectional view of a battery pack.

[0041] Figure 3 and Figure 4 is a cross-sectional view of a battery pack according to an exemplary embodiment of the present disclosure.

[0042] Figure 5 is a cross-sectional view of a battery pack according to an exemplary embodiment of the present disclosure.

[0043] FIG. 6 is a perspective view of a battery assembly accommodated in a battery pack according to an exemplary embodiment.

[0044] Figure 7 is a perspective view of a battery assembly according to an exemplary embodiment.

[0045] Figure 8 is a perspective view of a battery assembly according to another exemplary embodiment.

[0046] Fig. 9 is a perspective view of a battery assembly according to yet another exemplary embodiment.

[0047] Fig.10 It is shown Fig. 9 A three-dimensional diagram of the connection relationship of the battery components.

[0048] Fig.11 is an exploded perspective view of a battery assembly according to yet another exemplary embodiment.

[0049] Fig.12 It is shown Fig.11 A three-dimensional view of the bottom plate of the lower shell of the battery assembly.

[0050] Fig.13 yes Fig.11 A top perspective view of a battery assembly.

[0051] Fig.14 yes Fig.11 Bottom perspective view of the battery assembly.

[0052] Fig.15 and Fig.16 is a cross-sectional view of a battery pack according to still another exemplary embodiment of the present disclosure.

[0053] Fig.17 is a perspective view of a battery assembly according to yet another exemplary embodiment.

[0054] Fig.18 is a schematic diagram showing the structure of an electric vehicle equipped with a battery pack according to the present disclosure. DETAILED DESCRIPTION

[0055] 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 this specification and the appended claims should not be interpreted as limited to the general meaning and dictionary meaning, but should be interpreted based on the meaning and concept corresponding to the technical aspects of the present disclosure on the basis that the inventor can appropriately define the concept of the term in order to explain the principle of his or her disclosure in the best way.

[0056] Therefore, the exemplary embodiments described in the specification and the configurations shown in the drawings are only the most exemplary embodiments of the present disclosure and do not represent all technical ideas of the present disclosure. Therefore, it should be understood that various equivalents and modifications may exist to replace them when filing this application.

[0057] Furthermore, in describing the present disclosure, when it is determined that a detailed description of a related known function or configuration may obscure the gist of the present disclosure, the detailed description will be omitted.

[0058] The exemplary embodiments of the present disclosure are provided to more fully describe the present disclosure to those skilled in the art, and for a clearer description, the shapes and sizes of the components in the drawings may be exaggerated, omitted or schematically shown. Therefore, the sizes or ratios of the components do not fully reflect the actual sizes or ratios.

[0059] The subject matter of the present specification will now be more fully described hereinafter with reference to the accompanying drawings, which form a part hereof and show by way of illustration specific exemplary embodiments. An embodiment or implementation described herein as "exemplary" should not be construed as preferred or advantageous, e.g., over other embodiments or implementations; rather, it is intended to reflect or indicate that the embodiment is an "example" embodiment. The subject matter may be embodied in a variety of different forms, and thus, the subject matter covered or claimed is intended to be construed as not limited to any exemplary embodiment set forth herein; the exemplary embodiments are provided merely as illustrative. Likewise, a reasonably broad scope of the subject matter claimed or covered is intended.

[0060] Throughout the specification and claims, terms may have subtle meanings that are suggested or implied by the context beyond the explicitly stated meanings. Likewise, the phrase "in one embodiment" as used herein does not necessarily refer to the same embodiment, and the phrase "in another embodiment" as used herein does not necessarily refer to a different embodiment. For example, the claimed subject matter includes, in whole or in part, a combination of the exemplary embodiments.

[0061] The terms used below may be interpreted in their broadest reasonable manner, even though they are used in conjunction with the detailed description of certain specific examples of the present disclosure. Indeed, certain terms may even be emphasized below; however, any term intended to be interpreted in any limited manner will be explicitly and specifically so defined in this detailed description section. The foregoing general description and the following detailed description are exemplary and illustrative only and are not limiting of the features as claimed.

[0062] In the present disclosure, the term "based on" means "based at least in part on". Terms including ordinal numbers such as "first", "second", etc. can be used to distinguish one element from another in various elements, but are not intended to limit elements by terms. The singular forms "one", "an", and "the" include plural indicators unless the context otherwise dictates. The term "exemplary" is used in the sense of "example" rather than "ideal". The term "or" is intended to be inclusive and means any one, any one, several or all of the listed items. The terms "comprises", "comprising", "including", "including" or other variations thereof are intended to cover non-exclusive inclusions, so that a process, method or product including a series of elements does not necessarily include only those elements, but may include other elements that are not explicitly listed or inherent to such processes, methods, articles or devices. Relative terms (such as, "substantially" and "usually") are used to indicate possible variations of ±5% of the values ​​described or understood.

[0063] Furthermore, throughout the specification, when a part is referred to as being “connected” or “coupled” to another part, it is not limited to the case where they are “directly connected” or “directly coupled” but also includes the case where they are “indirectly connected” or “indirectly coupled” with one or more elements arranged therebetween.

[0064] Figure 1 and Figure 2 is a cross-sectional view of the battery pack 10 .

[0065] As shown in the figure, in the battery pack 10, the battery assembly 1 (such as a battery module) can be installed in the lower battery pack housing 2 including the substrate 2b (bottom plate). The top plate (battery pack cover) 2a can be installed on the upper part of the lower battery pack housing 2 to cover the battery module. When the battery pack 10 is installed in the vehicle, the passenger compartment can be set above the top plate 2a. In addition, the vehicle frame can be positioned below the substrate 2b, and thus the battery pack 10 can be installed on the vehicle frame.

[0066] Figure 3 and Figure 4 is a diagram for describing a battery pack according to an exemplary embodiment of the present disclosure.

[0067] The battery pack 100 of the present exemplary embodiment includes a battery assembly 110 and a pack case 120 .

[0068] exist Figure 3 and Figure 4 , the X direction indicates the longitudinal direction of the battery assembly 110. The Y direction indicates the width direction of the battery assembly. The Z direction indicates the height direction of the battery pack. The ZT direction is the direction toward the top of the Z direction, and the ZB direction is the direction opposite to the ZT direction. The battery assembly 110 may be a battery assembly 110 of FIG. 6( a) to FIG. 6( b) according to an embodiment of the present disclosure. Fig.14 Any of the battery assemblies shown, but not limited to these.

[0069] For clarity of explanation and illustration, battery assembly 110 will be described below with respect to battery assembly 110A shown in FIG6(a). Thus, battery assemblies 110 and 110A are interchangeably referenced with respect to FIG6(a). However, battery assembly 110 of the present disclosure is not limited to battery assembly 110A.

[0070] 6( a ), a battery assembly 110A may include a plurality of battery cells 111 a .

[0071] The plurality of battery cells 111a may be a basic unit of a lithium ion battery (e.g., a secondary battery). Each of the plurality of battery cells 111a may include an electrode assembly, an electrolyte, and a housing. Depending on the configuration of the electrode assembly and the electrolyte, the plurality of battery cells 111a may be classified as a lithium ion battery, a lithium ion polymer battery, a lithium polymer battery, etc. Lithium ion polymer batteries are increasing their market share among secondary batteries because lithium ion polymer batteries are less likely to leak electrolytes and are easy to manufacture.

[0072] Each of the plurality of battery cells 111a may be any of a cylindrical battery cell, a prismatic battery cell, or a pouch-type battery cell, but is not limited thereto. The electrode assembly of the cylindrical battery cell may be arranged or embedded in a cylindrical metal can. The electrode assembly of the prismatic battery cell may be arranged or embedded in a prismatic metal can. However, any other suitable shape, size, and / or material for the can may be utilized. The electrode assembly of the pouch-type battery cell may be arranged or embedded in a pouch housing including an aluminum laminate.

[0073] The electrode assembly arranged or embedded in the battery housing may include a positive electrode, a negative electrode, and a separator between the positive electrode and the negative electrode. Depending on the form or shape of the electrode assembly, the electrode assembly may be classified as a roll-type electrode assembly or a stacked electrode assembly. The roll-type electrode assembly may be formed by winding the positive electrode, the negative electrode, and the separator therebetween. The stacked electrode assembly may include a plurality of positive electrodes, a plurality of negative electrodes, and a plurality of separators therebetween.

[0074] According to an exemplary embodiment, a plurality of battery cells 111a may be connected in series and / or in parallel. For example, a plurality of battery cells 111a may be connected in series. Alternatively, a plurality of battery cells 111a may be connected in parallel. Additionally or alternatively, a plurality of battery cells 111a connected in parallel may form a group, and a group of a plurality of battery cells 111a may be connected in series.

[0075] A plurality of battery cells 111a may be grouped together to obtain a required or desired capacity. For example, a plurality of prismatic battery cells or a plurality of pouch-type battery cells may be stacked to form a battery cell assembly in the form of a cell stack. A plurality of cylindrical battery cells may be inserted through a plurality of insertion holes of a support frame mounted in a module housing to form a battery cell assembly.

[0076] In some embodiments, the battery cell assembly 111 may include compression pads between the battery cells 111a to prevent expansion. Alternatively, a thermal barrier may be provided between the battery cells 111a. For example, the thermal barrier may include a flame retardant material, such as a ceramic or coated glass material.

[0077] The battery assembly 110A may further include a bus bar (e.g., B) for electrically connecting the plurality of battery cells 111a to each other. The bus bar may include an inter-bus bar connected to the battery cells to electrically connect the battery cells 111a together, or may include a terminal bus bar for electrically connecting the battery assembly to an external electrical device.

[0078] The bus bar may be mounted on the bus bar frame. For example, the bus bar frame BFA may be disposed on at least one side surface of the battery cell assembly 111. The bus bar frame BFA may be disposed on one side surface of the battery cell assembly 111 (e.g., a battery cell stack) of a pouch-type battery cell. In the case of a battery cell assembly including pouch-type battery cells (electrode leads are pulled out from the pouch-type battery cells in a single direction), the bus bar frame may be disposed on one side of the cell stack (e.g., a side surface of the cell stack), and the electrode leads may be pulled out from one side of the cell stack. In the case of a battery cell assembly including pouch-type battery cells (electrode leads are pulled out from the pouch-type battery cells in multiple directions (e.g., two directions), the bus bar frame may be disposed on multiple side surfaces (e.g., front and rear surfaces) of a stacked form from which electrode leads may be drawn.

[0079] Alternatively, in the case of a prismatic battery cell, since electrode leads are generally pulled out from one surface (eg, an upper surface) of a stack, a bus bar frame may be provided on one surface.

[0080] In the case of a cylindrical battery cell, the bus bar may be provided on a side of the battery cell assembly from which the electrode terminal may be pulled out. In this case, each bus bar may be mounted on a structure such as a bus bar frame.

[0081] The end plate 114 may be provided to cover the bus bar frame BFA or to cover at least one side surface of the battery cell assembly. For example, in the case of a pouch type battery cell stack, the end plates 114, 115 may be provided to cover the bus bar frame BFA.

[0082] In the case of a prismatic battery cell, an end plate may be installed at each of a front end and a rear end of the battery cell in a stacking direction, but is not limited thereto.

[0083] According to an exemplary embodiment, the battery assembly 110 may further include a housing or a case for accommodating the battery cell assembly 111 and the bus bar frame BFA.

[0084] For example, the housings may be module housings 112 and 113 , and the battery assembly 110 may be a battery module.

[0085] As shown in Figure 6(a), the battery assembly 110 can have a shape in which at least a portion of the module housings 112 and 113 surrounding the upper, lower, left and right sides of multiple battery cells or the battery cell assembly 111 include an opening at the side where the bus bar frame BFA is provided.

[0086] In some embodiments, the battery pack of the present disclosure may not include the module cases 112 and 113 surrounding the upper side, the lower side, the left side, and the right side of the battery cell or the battery cell assembly 111 .

[0087] Alternatively, a housing or casing may be provided to cover only some of the upper side, lower side, left side, and right side of the battery cell or battery cell assembly 111. For example, two side panels may be provided to cover the left and right sides of the battery cell or battery cell assembly 111. In this case, the upper surface and / or lower surface of the battery cell or battery cell assembly 111 may be open or exposed.

[0088] Refer to Figure 3 The battery pack housing 120 may include a space for accommodating the battery assembly 110. The battery pack housing 120 may include a lower battery pack housing 120B, and the lower battery pack housing 120B includes a bottom plate 121 (e.g., Figure 3 The lower battery pack housing 120B is shown as having a bottom side or wall) and a top plate (or lid or cover) 120A coupled to cover the lower battery pack housing 120B.

[0089] like Figure 3 As shown, the bottom plate 121 may form the bottom or side of the battery pack and may be supported by the vehicle frame when the battery pack 100 is installed in the vehicle. Side walls 122 and 123 may be provided around the bottom plate 121. Figure 3 and Figure 4 1, the side walls 122 and 123 are shown on both sides of the bottom plate 121. However, the side walls may also be provided on the front and rear surfaces of the bottom plate 121. For the sake of clarity of illustration and explanation, the side walls at the front and rear surfaces are not shown. Figure 3 and Figure 4 As shown in . The bottom plate 121 and the side walls at the front side, the rear side and both sides may constitute the lower battery pack housing 120B. The bottom plate 121 and the side walls may be connected to each other by, for example, such a friction stir welding method, but are not limited thereto. Although terms such as front, rear, left, right, etc. are used throughout this disclosure to describe the position, location and / or orientation of various components of the battery pack 100, the various components may also be referred to by using ordinal numbers such as "first", "second?", etc. to distinguish one position, location and / or orientation from another position, location and / or orientation, but it is not intended to limit the position, location and / or orientation by terms.

[0090] The top plate 120A may be coupled to an upper portion of the lower pack housing 120B. That is, the top plate 120A may be a pack cover for covering the lower pack housing 120B and the battery assembly 110.

[0091] A passenger compartment of the vehicle may be located above the roof panel 120A.

[0092] The upper surface of the battery assembly 110 may be suspended and supported by the top plate 120A, or attached or fixed to the top plate 120A. That is, the battery assembly 110 may be coupled to the lower surface of the top plate 120A. In addition, a free volume FV is provided between the lower surface of the battery assembly 110 and the bottom plate 121. That is, the free volume FV may be defined as a separation space provided between the exposed portion of the battery assembly 110 and the bottom plate 121 opposite to the top plate 120A, such as Figure 3 For example, the battery assembly 110 may be spaced a certain distance from the surface of the bottom plate 121. In some embodiments, the distance between the bottom plate 121 and the battery assembly 100 may be selected within the range of 5 mm to 30 mm, 8 mm to 20 mm, or 10 mm to 16 mm, but is not limited thereto.

[0093] If the base plate is thick or the rigidity of the base plate is high, the height can be reduced.

[0094] Therefore, the battery pack 100 of the present disclosure has a supporting structure in which the battery assembly 110 is suspended and supported by the top plate 120A. In addition, a free volume FV may be provided between the bottom (bottom plate 121) of the battery pack and the battery assembly 110. Therefore, any gas and flame generated, for example, in the case of thermal runaway may move or communicate in or through the free volume FV. That is, the free volume FV becomes an exhaust path through which high-temperature gas and flame may move.

[0095] In addition, even if a strong impact occurs when a foreign object hits the lower part of the vehicle while driving on a hard surface (such as an unpaved road), the impact can be absorbed by the free volume FV. Therefore, the battery assembly 110 can be prevented from being damaged by the impact. The free volume FV can be defined as the empty space between the lower surface of the battery assembly 110 and the inner surface of the bottom plate 121. In addition, the empty space can be referred to as the free volume FV in the sense that even if the bottom plate 121, etc. is deformed toward the battery assembly 110 due to an external impact from below, the deformation can be allowed to a certain extent in the space. In one embodiment, the free volume FV may not include any structural components. Alternatively, a structure for supporting the battery assembly 110, etc. may be installed in a portion of the free volume FV. In one embodiment, when the structure is installed in a portion of the free volume FV, a volume or distance sufficient to allow deformation of the bottom plate 121, etc. can be provided between the battery assembly 110 and the bottom plate 121.

[0096] In one embodiment, the height of the free volume FV (i.e., the length or distance between the bottom plate 121 and the battery assembly 110) may be provided as needed to adequately absorb the impact. The height of the free volume FV may vary depending on the measurement location on the bottom plate 112. For example, the height or distance of the free volume FV between the mounting portion 122a or 123a and the inner surface of the bottom plate 112 may be greater than the height or distance between the bottom surface of the battery assembly 110 and the inner surface of the bottom plate 112, as shown in FIG. Figure 3 As shown, the change in height or distance in the free volume FV is not limited thereto. In some embodiments, the distance between the bottom plate 121 and the battery assembly 100 can be selected within the range of 5 mm to 30 mm, 8 mm to 20 mm, or 10 mm to 16 mm, but is not limited thereto.

[0097] The height of the free volume FV can be determined based on the thickness and rigidity of the vehicle frame or the bottom plate 121, the specifications or dimensions of the battery pack, and the amount and discharge rate of the gas generated during thermal runaway. For example, when the thickness of the vehicle frame or the bottom plate 121 is large or its rigidity is strong, the size or height of the free volume FV can be relatively reduced. When the thickness is small or the rigidity is weak, the possibility of deformation of the bottom plate 121 is high, so it is necessary to increase the height of the free volume FV to protect the battery assembly 110. In one embodiment, the thickness of the bottom plate 121 can be selected in the range of 1mm to 5mm. In another embodiment, the thickness of the bottom plate 121 ranging from 1mm to 3mm can be used. Alternatively, for example, if the bottom plate 121 is made of steel, the thickness of the bottom plate can be reduced to 0.8mm. Of course, the thickness of the bottom plate 121 is not limited to the above range, and can be selected to have any suitable thickness based on the application and design of the battery pack.

[0098] In addition, when the size of the battery pack is large according to the specifications of the battery pack, a relatively large free volume FV can be ensured. When the size of the battery pack is small, since the ensured free volume FV may be small, the thickness and rigidity of the bottom plate 121 may need to be relatively increased.

[0099] In addition, when the size / height of the free volume FV is too small, the gas discharge space becomes small, so the internal pressure of the battery pack may increase rapidly during thermal runaway. Therefore, the size and height of the free volume FV can be determined in consideration of the amount of gas generated and the discharge speed.

[0100] The maximum height of the free volume can be determined based on the degree of damage that the battery cell can withstand while preventing or reducing potential damage to the battery assembly or preventing or reducing thermal runaway. For example, when the damage tolerance of the battery cell is 1 mm, the free volume FV can be determined so that the battery cell does not deform more than 1 mm when the bottom plate is deformed and may press or contact the lower surface of the battery cell. In this case, the amount of deformation of the bottom plate may vary according to the thickness or rigidity of the bottom plate 121. Therefore, the size or height of the free volume can be determined by considering both the tolerance limit of the battery cell and the thickness and rigidity of the bottom plate. In addition, when the battery cell is housed in a separate housing (e.g., a module housing) inside the battery pack, even when the bottom plate is impacted, the possibility of damaging the battery cell protected by the module housing is further reduced. Therefore, in this case, the height of the free volume can be made smaller.

[0101] The upper surface of the battery assembly 110 may be tightly coupled to the lower surface of the top plate 120A. When there is a space between the battery assembly 110 and the top plate 120A, high temperature gas may be introduced into the space during thermal runaway, and thus heat and flames may propagate to the battery assembly 110. In addition, heat and flames may be transferred to the top plate 120A and affect the passenger compartment above the top plate 120A. Therefore, the upper surface of the battery assembly 110 may be tightly coupled to the lower surface of the top plate 120A, so that the gas or flame generated inside the battery pack will be guided to the free volume FV below the battery assembly 110 and transmitted through the free volume.

[0102] Still refer to Figure 3 , a thermal interface material (TIM) layer 130 including a thermal resin may be disposed between the battery assembly 110 and the top plate 120A. The TIM layer 130 may be inserted between the battery assembly 110 and the top plate 120A. The TIM layer 130 may fix or couple the battery assembly 110 and the top plate 120A to each other. Therefore, the battery assembly 110 may be closely coupled to the lower surface of the top plate 120A and supported on the lower surface of the top plate 120A through the TIM layer 130. In addition, the TIM layer 130 may prevent the formation of an air layer between the battery assembly 110 and the top plate 120A. The TIM layer 130 may be configured to transfer heat between the battery assembly 110 and the top plate 120A. Therefore, the heat generated from the battery assembly 110 may be transferred toward the top plate 120A. When the top plate 120A is equipped with an appropriate cooling device, the heat from the battery assembly 110 may be transferred to the cooling device through the TIM layer 130.

[0103] As cooling means, a plurality of cooling channels CH1 may be provided in the top plate 120A.

[0104] like Figure 3and Figure 4 As shown, the top plate 120A may include a plurality of cooling channels CH1 and a plurality of cavities C. Each of the plurality of cooling channels CH1 and the plurality of cavities C may extend in the Y direction.

[0105] According to an exemplary embodiment, the plurality of cooling channels CH1 may be configured to provide a path through which a cooling fluid may flow. The cooling fluid may be a fluid for cooling the plurality of battery assemblies 110, such as water, air, or a coolant, but is not limited thereto. The plurality of cooling channels CH1 may be spaced apart from each other in the X direction. The plurality of cooling channels CH1 may be interposed between the plurality of cavities C.

[0106] The plurality of cavities C are empty spaces formed inside the top plate 120A. Due to the formation of the plurality of cavities C, the weight of the top plate 120A may be reduced, and thus the energy density of the battery pack 100 may be increased. In one embodiment, the energy density of the battery pack 100 may be defined as follows:

[0107] Energy density of battery pack=capacity of battery pack / weight of battery pack The plurality of cavities C may be spaced apart from each other in the X direction.

[0108] Although not shown in the drawings for clarity of illustration and explanation, the cooling channel CH1 may be connected to a vehicle cooling system. In one embodiment, a cooling port may be connected to the cooling channel CH1. The cooling port may be connected to the vehicle cooling system through a pipe or the like.

[0109] When the TIM layer 130 is disposed between the upper surface of the battery assembly 110 and the top plate 120A, and the cooling channel CH1 is disposed in the top plate 120A, any heat generated by the battery assembly 110 can be efficiently dissipated. In addition, when the TIM layer 130 and the cooling channel CH1 are disposed on the upper side of the battery pack, the heat generated in the battery pack 100 can be prevented or reduced from being transferred toward the passenger compartment. Therefore, the safety of the electric vehicle can be improved.

[0110] exist Figure 3 and Figure 4 In the battery pack 100, the battery assembly 110 is fixed to the top plate 120A by an adhesive member such as a TIM layer 130. However, considering the load of the battery assembly 110, the top plate 120A and the battery assembly 110 may be fastened by a fastening member. For example, when the battery assembly 110 includes module housings 112 and 113, the top plate 120A and the module housings 112 and 113 may be fastened by a fastening member, and thus the battery assembly 110 may be suspended and supported by the top plate 120A. Alternatively, the battery assembly 110 may be coupled to the top plate 120A using both the TIM layer 130 and the fastening member. In this case, the load of the battery assembly 110 may be more evenly distributed to the top plate 120A.

[0111] If necessary, the battery assembly 110 may be coupled to the lower battery pack housing 120B. For example, the side wall of the lower battery pack housing 120B may be coupled to the side surface of the battery assembly 110. In this case, the assembly mounting portions 122a and 123a may be provided on the side walls 122 and 123 to support the side surface of the battery assembly. The assembly mounting portions 122a and 123a may protrude from the side walls 122 and 123 to support the side surface of the battery assembly that is perpendicular to the upper surface of the battery assembly 110. To this end, the assembly mounting portions 122a and 123a may extend in the X direction, the Y direction, or the X and Y directions. When the assembly mounting portions 122a and 123a extend in the Y direction, the assembly mounting portions 122a and 123a may be provided on the front and rear side walls (not shown) of the lower battery pack housing 120B.

[0112] The side surfaces of the component mounting portions 122a and 123a facing the battery assembly 110 can be in close contact with the side surfaces of the battery assembly to support the battery assembly 110. In this case, since the upper surface of the battery assembly is supported by the top plate 120A and its side surface is supported by the component mounting portions 122a and 123a, the load of the battery assembly 110 can be easily dispersed. Therefore, even a heavier battery assembly 110 can be firmly supported in the battery pack 100. Even when the TIM layer is not used or the TIM layer is used, the battery assembly 110 can be connected to the top plate 120A and / or the component mounting portions 122a and 123a. For example, the battery assembly 110 can be fastened or welded and connected to the top plate 120A and / or the component mounting portions 122a and 123a by a fastening member. Alternatively or additionally, the battery assembly 110 can be fixed to the top plate 120A using an adhesive material.

[0113] In one embodiment, the top plate 120A may be placed on the upper surface of the component mounting portions 122a and 123a. In addition, the top plate 120A may be coupled to the side walls 122 and 123 of the lower battery pack housing 120B. In this example, the component mounting portions 122a and 123a may be provided to distribute the load of the top plate 120A and to mount the top plate 120A. The component mounting portions 122a and 123a may extend from the side walls toward the interior of the battery pack. Figure 3As shown, a space can be provided between the upper ends of the side walls 122, 123 and the upper surfaces of the component mounting portions 122a and 123a, and the top plate 120A can be placed in the space. That is, the top plate can be placed in a space arranged above the upper surfaces of the component mounting portions 122a and 123a, and supported by the component mounting portions 122a and 123a. The top plate 120A can be connected to the upper surfaces of the component mounting portions 122a and 123a and / or the side walls 122 and 123 by fastening members, welding, etc. Therefore, the load of the top plate 120A can be more evenly distributed to the lower battery pack housing 120B. The component mounting portions 122a and 123a provide a supporting surface for both the battery assembly and the top plate. Therefore, the battery assembly and the top plate can be supported by the component mounting portions 122a and 123a at the same time.

[0114] The assembly mounting portions 122a and 123a may also be used to block gas in the battery pack from moving to the top plate 120A. For example, the assembly mounting portions 122a and 123a are formed in the form of a quadrilateral or rectangular frame surrounding the battery assembly 110, thereby preventing gas from directly contacting the top plate 120A.

[0115] In one embodiment, in order to distribute the load of the battery assembly and ensure the free volume FV, a predetermined supporting structure may be further provided on the bottom plate 121 .

[0116] Reference Figure 5 According to an embodiment of the present disclosure, a plurality of battery supports 150 may be disposed on the bottom plate 121 of the lower battery pack housing 120B.

[0117] In one embodiment, the battery support 150 has a height in the Z direction. Therefore, the battery assembly 110 may be supported by the battery support such that the upper surface of the bottom plate 121 is spaced apart from the battery assembly 110. The height of the battery support 150 may be adjusted to adjust the height and size of the free volume FV.

[0118] Corresponding coupling portions that can be coupled to the battery support 150 may be provided on the front and rear surfaces and / or side surfaces of the battery assembly 110. For example, Figure 5 As shown, the protruding coupling portion F1 fastened to the battery support 150 may be provided on both side surfaces of the battery assembly. Figure 6B As shown, protruding coupling portions F2 fastened to the battery support 150 may be provided on the front and rear surfaces of the battery module 110A. Predetermined fastening holes, into which fastening members may be fastened, may be formed in the protruding coupling portions F1 and F2 and the battery support.

[0119] Still refer to Figure 5When the battery assembly 110 is coupled to the battery support 150 and the assembly mounting portions 122a and 123a and the top plate 120A of the lower battery pack housing 120B by adhesive members (e.g., TIM layer 130) and fastening members, even a heavier battery assembly 110 can be installed in the battery pack.

[0120] Still refer to Figure 5 , the battery assemblies 110 may be installed in two rows in the Y direction, but the present disclosure is not limited thereto. One or more rows of battery assemblies 110 may be arranged along the Y direction. Alternatively, one or more battery assemblies 110 may also be arranged along the X direction.

[0121] The battery support 150 may occupy part of the free volume FV, for example Figure 5 The battery supports 150 may be arranged at various intervals in the battery pack 100 to allow the bottom plate 121 and the like to deform when an external impact or force is applied to the bottom plate 121. For example, the space between the battery supports 150 may become part of the free volume FV.

[0122] Refer to Figure 3 and Figure 4 , the lower battery pack housing 120B may include an exhaust device 140 on one or more side walls at the front, rear, left and right sides. In one embodiment, the exhaust device 140 may be disposed on the side walls 122 and 123, such as Figure 3 and Figure 4 The side wall may include exhaust passages and / or exhaust holes connected to the exhaust device 140. The exhaust passages and exhaust holes may be configured to provide a path for exhausting or transferring gas and heat from the interior of the battery pack 100.

[0123] When at least one of the plurality of battery assemblies 110 is in a thermal runaway state, the exhaust device 140 may be configured to discharge or transfer the high temperature gas inside the battery pack 100 to the outside and delay heat propagation. In this case, the free volume FV becomes a path for quickly moving or transferring the gas to the exhaust device 140.

[0124] The battery pack 100 may also include electrical components (not shown in the figure for clarity of illustration and explanation). The electrical components may be disposed on the lower battery pack housing 120B. The electrical components may be disposed between the battery assembly 110 and the side wall where the exhaust device 140 may be mounted. The electrical components may include any electronic devices required to drive the battery pack.

[0125] The electrical components may include, for example, a battery management system (BMS). The BMS may be configured to monitor, balance, and control the battery pack.

[0126] The electrical components may further include a cooling device, a power relay assembly (PRA), a safety plug, etc. The cooling device may include a cooling fan. The cooling fan may circulate air inside the battery pack 100 to prevent each of the plurality of battery assemblies 110 from overheating.

[0127] Figure 6 to Fig.10 is a perspective view of a battery assembly accommodated in a battery pack according to an exemplary embodiment.

[0128] Fig. 6A and Figure 6B The battery assembly is shown and an exploded perspective view of the battery module 110A is shown (see Fig. 6A ) and combined stereograms (see Figure 6B ).

[0129] The battery module 110A includes a battery cell assembly 111 , module cases 112 and 113 for accommodating the battery cell assembly 111 , and end plates 114 and 115 coupled to front and rear surfaces of the module cases 112 and 113 .

[0130] The battery cell assembly 111 may be formed, for example, by stacking a plurality of pouch-type battery cells 111a Alternatively, the battery cell assembly 111 may be formed by stacking a plurality of prismatic battery cells or any other suitable battery cells that may be arranged to form a battery cell assembly.

[0131] The module housing may include a lower housing 112 and an upper housing 113. FIG6 shows a U-shaped frame including side plates 112b and a bottom plate 112a as the lower housing 112. The shapes of the module housings 112 and 113 are not limited to those shown in FIG6, and of course, other types of module housings may be applied as long as the module housing accommodates the battery cell assembly 111.

[0132] The bus bar frame BFA may be coupled to the front and rear surfaces of the battery cell assembly 111. Bus bars B for connecting electrode leads of the battery cells 111a, bus bars B for electrical connection to another battery module or the outside, etc. may be mounted on the bus bar frame BFA.

[0133] Front and rear plates 114 and 115 for protecting the bus bar frame BFA and the battery cell assembly 111 may be located on the front and rear surfaces of the battery cell assembly 111. The front and rear plates 114 and 115 may be coupled to the module housings 112 and 113 and / or the bus bar frame BFA.

[0134] If necessary, the module cases 112 and 113 (eg, the upper case 113 ) may be provided with exhaust holes H to exhaust gas in the module.

[0135] A TIM layer 130' including a thermal resin may be disposed on the bottom plate 112a of the lower housing 112. The TIM layer 130' may be made of the same or different material as the above-mentioned TIM layer 130 disposed between the battery assembly 110 and the top plate 120A. The TIM layer 130' on the bottom plate may fix or attach the battery cell assembly 111 to the bottom plate 112a. In addition, the TIM layer 130' may transfer heat from the battery cell assembly 111 to the bottom plate and the lower housing 112.

[0136] In one embodiment, in addition to or instead of the TIM layer 130 ′, a TIM layer may be located on the inner surface of the upper case 113 . That is, the TIM layer may be disposed between the upper case 113 and the upper surface of the battery cell assembly 111 .

[0137] The battery cell assembly 111 may be installed in the lower case 112 of the U-shaped frame, and the upper case 113 may be coupled to the lower case 112 by welding or the like, so that the battery cell assembly 111 may be accommodated between the module cases 112 and 113. A bus bar frame BFA may be provided on the front and rear surfaces of the battery cell assembly 111, and a front end plate 114 and a rear end plate 115 may be coupled thereto, thereby forming a Figure 6B The battery module is shown.

[0138] The cooling device may be provided in at least one of the upper case 113 and the lower case 112. For example, the cooling device may be formed as a structure in which two plates are coupled at a gap in the upper case 113 or the bottom plate 112a of the lower case opposite to the upper case 113. In this case, a partition wall may be formed in the gap, and a cooling channel CH2 as the cooling device may be provided in the partition wall. The cooling channel may be provided on the case side where the TIM layer 130' is formed.

[0139] If necessary, such as Fig.12 As shown, the TIM layer 130 ′ and the cooling channel CH2 may be disposed in both the upper housing 113 and the lower housing 112 .

[0140] Reference Figure 6B , the battery module 110A may include a coupling portion F2 to couple to a corresponding structure in the battery pack 100, for example, the battery support 150. The coupling portion F2 having fastening holes h2 is provided at both sides of the end plate of the battery module and coupled to the battery support or the like.

[0141] A plurality of battery modules 110A may be provided in the battery pack 100 .

[0142] As in Fig. 6A and Figure 6BIn the battery module 110A shown in FIG. 1 , when the TIM layer 130 ′ is disposed in the lower housing 112 , preferably, the bottom plate 112 a of the lower housing is coupled to the Figures 3 to 5 The top plate 120A of the battery pack shown. That is, the upper case 113 of the module may be installed to face the bottom plate 121 of the battery pack 100, and the bottom plate 112a may be installed to face the top plate 120A. Therefore, the heat generated from the battery cell assembly 111 may be transferred to the lower case 112 through the TIM layer 130'. The heat transferred to the lower case 112 may be transferred to the TIM layer 130 provided on the top plate 120A, and then may be dissipated by the cooling device of the top plate 120A.

[0143] Figure 7 A battery cell assembly 111 and a battery assembly 110B are shown, wherein a busbar frame BFA and end plates 114 and 115 are coupled to the front and rear surfaces of the stack. The battery assembly 110B has a module-free structure, wherein there is no module housing covering the upper, lower, left, and right surfaces of the battery cell assembly 111.

[0144] The battery cells 111a are stacked so that the side surfaces are in contact with each other, as shown in FIG. Figure 7 As shown, the side surfaces of adjacent battery cells can be fixed to each other by double-sided tape. The fixing member can be used to fix the plurality of stacked battery cells 111a. For example, a band 116 can be used as a fixing member to bind the periphery of the battery cell assembly 111.

[0145] Figure 8 The battery cell assembly 111 and the battery assembly 110C are shown, wherein the bus bar assembly and the end plates 114 and 115 are coupled to the front and rear surfaces of the stack, and the first side plate 117 and the second side plate 117' are coupled to both side surfaces of the battery cell assembly 111. In the battery assembly 110C, the battery cell assembly 111 may also be bundled using a band 116 to fix the battery cells and the first side plate and the second side plate, as shown in FIG. Figure 8 shown.

[0146] The busbar frame BFA and the end plates 114 and 115 may be formed separately or integrally. Busbars B from the busbar frame BFA or a portion of the busbar frame BFA may be exposed at the end plates 114 and 115, and the end plates 114 and 115 may be electrically connected to other battery assemblies 110 through the busbars B.

[0147] exist Figure 7 and Figure 8In each of the battery assemblies 110B and 110C, the upper surface and the lower surface of the battery cell assembly 111 may be open or exposed. Therefore, one of the open or exposed upper and lower surfaces of the battery cell assembly 111 may be coupled to the lower surface of the top plate 120A of the battery pack 100. For example, the TIM layer 130 may be disposed between the top plate 120A and the battery cell assembly 111 to couple the battery assembly 110 to the top plate 120A. The other of the upper and lower surfaces of the battery cell assembly 111 may be disposed opposite to and facing the bottom plate 121 of the battery pack 100, and there may be a gap or space between the other surface and the bottom plate 121, and the gap or space may define a free volume FV.

[0148] Fig. 9 A battery assembly 110D is shown including a first side plate 117 and a second side plate 117 ′ having complementary structures that may be configured to engage with each other.

[0149] The structures of the battery cell assembly 111, the busbar frame BFA and the end plates 114 and 115 may be substantially similar to Figure 7 and Figure 8 The structures of the battery assemblies 110B and 110C are shown in FIG.

[0150] The first side plate 117 may be positioned on a first side surface (eg, a left side surface) of the battery cell assembly 111. Fig. 9 The second side plate 117' may be positioned on a second side surface (eg, right side surface) of the battery cell assembly 111, as shown. Fig. 9 shown.

[0151] The first side plate 117 and the second side plate 117' have complementary structures that can be easily joined to each other. Fig. 9 As shown, the first side plate 117 may have a stepped structure having a protrusion P on the upper side of the side surface and a recess Q on the lower side of the side surface. Fig. 9As shown, the second side plate 117' has a step structure having a protrusion P' at a lower portion of the side surface and a recess Q' at an upper portion of the side surface. The step structure of the first side plate 117 and the step structure of the second side plate 117' are configured to engage and match each other. Therefore, the first side plate 117 of one battery assembly 110D and the second side plate 117' of an adjacent battery assembly 110D that can face the first side plate 117 can engage with each other, and when the first side plate 117 and the second side plate 117' are connected by a fastening member, the adjacent battery assemblies 110D can be connected to each other. In order to connect the first side plate 117 and the second side plate 117', fastening holes 117a and 117a' can be formed at the same position of the side plates 117, 117'. That is, as Fig. 9 As shown, a plurality of fastening holes 117a may be formed through the upper surface of the protrusion P of the first side plate 117, and a plurality of fastening holes 117a' may be formed through the protrusion P' of the lower side of the second side plate 117' at positions corresponding to the fastening holes 117a. Therefore, a fastening member such as a bolt may pass through the fastening holes of the first side plate 117 and the second side plate 117' to be coupled, thereby coupling the first side plate 117 and the second side plate 117'.

[0152] Fig.10 The first side plate 117 and the second side plate 117' of the adjacent battery assembly 110D are shown to be connected to each other through the connection process described in the previous embodiment. The assembly of the first side plate 117 and the second side plate 117' can be a partition wall for separating adjacent battery cell assemblies 111, such as Fig.10 In one embodiment, the assembly of the first side plate 117 and the second side plate 117' can be connected to Figure 5 In this case, fastening members (such as bolts) may pass through the fastening holes of the first side plate 117 and the second side plate 117' and may be fastened together to corresponding fastening holes formed in the battery support 150, thereby coupling the first side plate 117 and the second side plate 117' to the battery support 150.

[0153] like Fig.10 As shown in the battery assembly 110D of FIG. 1 , the upper surface and the lower surface of the battery cell assembly 111 may be open or exposed. Therefore, one of the open upper and lower surfaces of the battery cell assembly 111 may be coupled to the lower surface of the top plate 120A of the battery pack 100. For example, the TIM layer 130 may be disposed between the top plate 120A and the battery cell assembly 111 to couple the battery assembly 110 to the top plate 120A. The other of the upper and lower surfaces of the battery cell assembly 111 may be disposed opposite to the bottom plate 121 of the battery pack 100 with a gap or space therebetween, and the gap or space may define a free volume FV.

[0154] Figures 7 to 10 The battery assemblies 110B, 110C, and 110D shown in FIG. 1 have a module-free structure in which at least a portion of the module housings 112 and 113 can be removed. Therefore, the removed portions of the module housings 112 and 113 can simplify the structure of the battery assembly 110 and can reduce the weight of the battery assembly 110. Therefore, the energy density of the battery pack 100 employing the battery assembly 110 can be further improved.

[0155] Mode for the Invention

[0156] Fig.11 is an exploded perspective view of a battery assembly according to another exemplary embodiment. Fig.12 It is shown Fig.11 A three-dimensional view of the bottom plate of the lower shell of the battery assembly. Fig.13 yes Fig.11 A top perspective view of a battery assembly. Fig.14 yes Fig.11 Bottom perspective view of the battery assembly.

[0157] Figures 11 to 14 The illustrated battery module 110E may have a similar shape to the battery module of FIG. 6 .

[0158] In one embodiment, Fig.11 The battery module 110E may include a battery cell assembly 111 , module cases 112 and 113 for accommodating the battery cell assembly 111 , and end plates 114 and 115 coupled to front and rear surfaces of the module cases 112 and 113 .

[0159] The two battery cell assemblies 111 are arranged in the longitudinal direction, and the rear surface of the front battery cell assembly 111 is coupled to the front surface of the rear battery cell assembly 111. In the example shown, the two battery cell assemblies 111 may be connected in the longitudinal direction (X direction), but the present disclosure is not limited thereto. Two or more battery cell assemblies 111 may be connected in the X direction.

[0160] Two or more battery assemblies 110 may also be disposed in the battery pack 100 in the longitudinal direction. However, in this case, the number of components coupled to each battery cell assembly 110 and the number of module cases for accommodating the battery cell assemblies 110 may increase. Therefore, the manufacturing cost may increase, and the assembly work of the battery assembly 110 may also become complicated.

[0161] In one embodiment, when the plurality of battery cell assemblies 111 are arranged in the longitudinal direction, as shown in FIG. Fig.11As shown, the longitudinal assembly of the battery cell assembly 111 is accommodated in one module housing (eg, 112 and 113), which can reduce the number of components and manufacturing costs.

[0162] The bus bar frame BFA may be coupled to the front and rear surfaces of each battery cell assembly 111, such as Fig.11 The bus bar frame BFA mounted on the rear surface of the front battery cell assembly 111 may be mechanically and electrically coupled to the bus bar frame BFA mounted on the front surface of the rear battery cell assembly 111 .

[0163] The front end plate 114 and the rear end plate 115 for protecting the bus bar frame BFA and the battery cell assembly 111 may be positioned on the front surface and the rear surface of the longitudinal assembly of the battery cell assembly 111. The front end plate 114 and the rear end plate 115 may be connected to the module housings 112 and 113 and / or the bus bar frame BFA. Although two battery cell assemblies 111 are provided, a pair of the front end plate and the rear end plate is sufficient. Therefore, the number of end plates can be reduced compared to the case where two battery assemblies 110 are installed in the longitudinal direction.

[0164] The module housing may include a lower housing 112 and an upper housing 113. A U-shaped frame including a side plate 112b and a bottom plate 112a as the lower housing 112 is shown. However, the shapes of the module housings 112 and 113 are not limited to Fig.11 The shape shown, of course, can be applied or utilized with other types of module housings as long as the module housing can properly accommodate the battery cell assembly 111 .

[0165] In one embodiment, the upper housing 113 may be provided with exhaust holes to exhaust the gas in the module.

[0166] A TIM layer 130' including a thermal resin may be disposed on the bottom plate 112a of the lower housing 112. The TIM layer 130' may be made of the same or different material as the above-mentioned TIM layer 130 disposed between the battery assembly 110 and the top plate 120A. The TIM layer 130' on the bottom plate 112a may fix the battery cell assembly 111 to the bottom plate 112a. In addition, the TIM layer 130' may transfer heat of the battery cell assembly 111 to the bottom plate 112a and the module housings 112 and 113.

[0167] If necessary, the TIM layer 130 ′ may be positioned on the inner surface of the upper case 113 . That is, the TIM layer 130 ′ may be disposed between the upper case and the upper surface of the battery cell assembly 111 .

[0168] The battery cell assembly 111 may be installed in the lower case 112 of the U-shaped frame, and the upper case 113 may be coupled to the lower case 112 by welding or the like, so that the battery cell assembly 111 may be accommodated in the module cases 112 and 113. The bus bar frame BFA may be provided on the front and rear surfaces of the battery cell assembly 111, and the front end plate 114 and the rear end plate 115 may be coupled thereto, thereby forming a Fig.13 and Fig.14 The battery module of the present exemplary embodiment is shown.

[0169] In one embodiment, the cooling device may be disposed in at least one of the upper housing 113 and the lower housing 112. For example, the cooling device may be formed as a structure in which two plates are connected together to form a cavity or space between the two plates. The cooling device may be disposed in the upper housing or in the bottom plate 112a of the lower housing opposite to the upper housing. For example, Fig.12 The bottom plate 112a having such a structure is shown. The bottom plate 112a may include an inner plate 112a-2 opposite to the battery cell assembly 111 and an outer plate 112a-1 opposite to the inner plate 112a-2. The inner plate 112a-2 and the outer plate 112a-1 may be molded to include protrusions and recesses having various patterns, such as Fig.12 However, any suitable protrusions, shapes and patterns may be used. Therefore, when the inner plate 112a-2 and the outer plate 112a-1 are coupled, the cooling channel CH2 may be formed between the inner plate 112a-2 and the outer plate 112a-1 by a combination of protrusions, a combination of protrusions and recesses, etc., as shown in FIG. Fig.12 As shown. For example, the cooling channel CH2 can be formed by the space or volume generated when 112a-1 and 112a-2 are connected together via any suitable bonding process (e.g., a brazing method). Therefore, a cooling channel CH2 is formed between the inner surface of the protrusion and the recess. For clear illustration and explanation, the protrusion and the recess are only shown on the upper surface of the outer plate 112a-1. However, the inner plate 112a-2 may also include a protrusion and a recess on the surface opposite to the upper surface of the outer plate 112a-1, but is not limited thereto. The cooling channel CH2 can be positioned in the housing in which the TIM layer 130' is formed.

[0170] In one embodiment, the TIM layer 130 ′ and the cooling channel CH2 may be provided in both the upper case 113 and the lower case 112 .

[0171] Reference Fig.13, the battery module 110E may include a coupling portion to be coupled to a corresponding structure (e.g., a battery support 150) in the battery pack 100. Along two side plates 112b of the lower case 112 (for clarity of illustration and explanation, only one side of the side plate 112b is shown, and the side plate 112b on the opposite side is not shown), a protruding coupling portion F1 having a fastening hole h1 may be provided to couple to the battery support 150. The protruding coupling portions F1 may be spaced apart from each other in the longitudinal direction of the battery module, such as Fig.13 The number and shape of the coupling parts provided on the left plate and the right plate 112b of the battery module 110E may be the same or different. Fig.13 In the side plate 112b, four protruding coupling portions F1 may be provided in the longitudinal direction. Fig.14 In the side plate 112 b , two protruding coupling portions F1 may be provided in the longitudinal direction, and a plurality of fastening holes h1 may be formed in each of the protruding coupling portions F1 .

[0172] In one embodiment, the plurality of battery modules 110E may be arranged in Figure 15 to Figure 16 In the battery pack 101 shown.

[0173] As in Fig.11 In the battery module 110E shown, when the TIM layer 130' and the cooling channel CH2 are provided in the lower shell, it is preferred that the bottom plate 112a of the lower shell 112 is coupled to the top plate 120A of the battery pack 100 or 101. That is, the upper shell 113 of the module can be installed to face the bottom plate 121 of the battery pack 100 or 101, and the bottom plate 112a can be installed in the battery pack to face the top plate 120A. Therefore, the heat of the battery cell assembly 111 can be transferred to the lower shell through the TIM layer 130' of the lower shell. The heat transferred to the lower shell 112 can be dissipated through the cooling channel CH2 of the lower shell 112.

[0174] Therefore, since the heat transferred from the battery module 110E to the roof panel 120A can be dissipated, the passengers in the passenger compartment can be protected.

[0175] In this embodiment, when the cooling device CH1 is disposed in the top plate 120A, this cooling effect can be further doubled. For example, since the cooling device is disposed in both the lower housing of the battery assembly 110 and the top plate 120A of the battery pack housing 120, the heat transferred to the upper part of the battery pack 100 or 101 can be more reliably dissipated. Therefore, the effect of protecting the passenger compartment is further doubled. For example, heat can be transferred through the path of the TIM layer 130' to the cooling channel CH2 to the TIM layer 130 to the cooling channel CH1.

[0176] Fig.15 and Fig.16 Yes Figures 11 to 14 1 is a cross-sectional view of a battery pack 101 of a battery assembly (battery module).

[0177] As shown, the bottom plate 112a of the lower case of the battery module 110E is suspended and supported by the top plate 120A of the battery pack through the TIM layer 130'. In addition, the upper surface of the upper case 113 of the battery module may be spaced apart from the bottom plate 121, and this separation space may form a free volume FV.

[0178] Two battery cell assemblies 111 may be mounted in the battery module 110E in the longitudinal direction, so that a required capacity may be obtained with a simple structure.

[0179] According to the battery pack of the present exemplary embodiment, even when an impact is applied to the battery pack 101 from below, the free volume FV can absorb, for example, deformation of the bottom plate 121 , so that damage to the battery assembly 110 can be prevented.

[0180] Furthermore, even when gas and flame are generated due to thermal runaway, the free volume FV serves as an exhaust path to quickly discharge or transfer the gas to the outside of the battery pack. Figure 3 As shown, the exhaust device 140 may be provided on the side wall of the battery pack, thereby facilitating the exhaust of gas.

[0181] In addition, a thermal resin layer such as a TIM layer 130 may be disposed on the lower surface of the top plate 120A of the battery pack to transfer heat from the battery module 110E to the top plate 120A. The top plate 120A may include a cooling channel CH1 so that heat can be dissipated or easily emitted to the outside.

[0182] Fig.17 is a perspective view of a battery assembly 110F according to another exemplary embodiment.

[0183] Fig.17 The structure of a battery assembly 110F including prismatic battery cells 111 a is shown.

[0184] Fig.17 The battery assembly 110F may include a battery cell assembly 111, a first side plate 117, a second side plate 117', a bus bar frame BFA, and a bus bar mounted on the bus bar frame BFA. In addition, an insulating cover IC may be provided on the bus bar B for insulation.

[0185] The prismatic battery cells 111a may be stacked in the X direction to form a battery cell assembly 111. A bus bar frame BFA (bus bar carrier) is provided on an upper surface of the battery cell assembly 111. Bus bars B (such as intermediate bus bars and terminal bus bars) may be mounted on the bus bar frame BFA. One or more strips (not shown for clarity if illustrated and explained) may be provided along the periphery of the battery cell assembly to fix the battery cell assembly 111. In addition, a front end plate 114 and a rear end plate 115 covering the front and rear ends of the battery cell assembly 111 may be provided, such as Fig.17 shown.

[0186] The first side plate 117 and the second side plate 117' may be provided with a coupling portion for coupling to a corresponding structure (e.g., a battery support 150) in the battery pack. That is, in the longitudinal direction (X direction) of the first side plate 117 and the second side plate 117', a protruding coupling portion F1 having a fastening hole h1 may be provided. In one embodiment, the protruding coupling portions F1 may be spaced apart from each other in the longitudinal direction of the battery module 110F. The number and shape of the coupling portions provided on the first side plate 117 and the second side plate 117' of the battery assembly 110F may be the same or different.

[0187] The battery assembly 110F of this exemplary embodiment can be accommodated in the battery pack housing 120 of the battery pack 100 or 101, and one surface of the battery assembly 110F can be suspended and supported by the top plate 120A of the battery pack housing. For example, at least one of the upper surface and the lower surface of the battery cell assembly 111 can be connected to the lower surface of the top plate 120A by, for example, the TIM layer 130. If necessary, the battery assembly 110F can be fastened to the top plate 120A and / or the lower battery pack housing 120B. Alternatively, the protruding connection portion F1 of the battery assembly 110F can be connected to a battery support 150 provided on the bottom plate 121 of the battery pack 100 or 101, thereby firmly supporting the battery assembly 110F in the battery pack. In this case, a free volume FV is provided between the lower surface of the battery assembly 110F and the bottom plate 121.

[0188] Although not shown, Fig.17 The battery assembly 110F may further include an upper case for covering an upper surface of the battery cell assembly 111 and / or a lower case for covering a lower surface of the battery cell assembly 111 .

[0189] For example, the upper housing may be positioned on the insulating cover IC. Alternatively, the lower housing may be positioned below the battery cell assembly 111. The upper housing and / or the lower housing may be coupled to the first side plate 117 and the second side plate 117'. In this case, the upper housing and the lower housing and the first side plate and the second side plate may form a module housing of the battery cell assembly 111.

[0190] The battery assembly 110F including the upper case or the lower case may be suspended and supported by the top plate 120A of the battery pack housing 100 or 101 .

[0191] In one embodiment, the cooling device may be disposed in the upper housing or the lower housing. For example, the housing including the cooling device may be coupled to the top plate 120A.

[0192] In one embodiment, the housing of the battery assembly 110F facing the free volume FV may have a vent hole. As a result, gas generated from the battery cell assembly 111 may be discharged to the outside of the battery assembly 110F.

[0193] Fig.18 is a schematic diagram showing the structure of an electric vehicle 200 equipped with a battery pack according to the present disclosure.

[0194] To simplify the description, only the vehicle body frame 210 constituting the lower frame of the vehicle, the battery pack 101 coupled to the vehicle body frame 210 , and the tires are shown.

[0195] The battery pack 100 or 101 according to the present disclosure can be mounted on the vehicle body frame 210. The battery pack 100 or 101 does not have a structure in which the battery assembly is mounted at the bottom of the battery pack as in the prior art, but has a structure in which the battery assembly 110 is suspended and supported by the top plate 120A of the battery pack. That is, since there is no space between the battery assembly (battery module 110E) and the top plate 120A, the gas generated from the battery assembly can be prevented from being transmitted to the passenger compartment on the upper side of the vehicle. The gas is guided to the free volume FV between the battery assembly 110 and the bottom plate 121 of the battery pack. That is, since there is no space above the battery pack, the gas is guided to the free volume FV below the battery pack. The gas can flow through the free volume FV to be discharged to the lower part of the vehicle through the exhaust device installed in the battery pack.

[0196] The bottom plate 121 of the battery pack is mounted or supported by the vehicle body frame 210. In this case, since the vehicle body frame 210 may be impacted at the lower side of the vehicle, the bottom plate 121 may be deformed. The battery pack of the present disclosure includes a free volume FV between the battery assembly 110 and the bottom plate 121. Therefore, even if the bottom plate 121 is deformed, the battery assembly 110 can be prevented from being damaged.

[0197] Therefore, according to the battery pack and the electric vehicle equipped with the battery pack of the present disclosure, the safety of passengers can be enhanced. In addition, the battery assembly 110 as a core component can be protected, and the durability of the battery pack and the electric vehicle can be improved.

[0198] The present disclosure is described in more detail above through the accompanying drawings and exemplary embodiments. However, the configurations described in the exemplary embodiments in the accompanying drawings or the specification are merely exemplary embodiments of the present disclosure and do not represent all technical concepts of the present disclosure. Therefore, it should be understood that various equivalents and modifications may exist to replace them when submitting this application.

[0199] [Explanation of Reference Numerals]

[0200] 100, 101: Battery pack

[0201] 110: Battery components

[0202] 120: Battery pack housing

[0203] 120A: Top plate

[0204] 120B: Lower battery housing

[0205] 130: TIM layer

[0206] 140: Exhaust

[0207] 200: Electric vehicles

[0208] 210: Body frame

Claims

1. A battery pack, comprising: a housing comprising an opening and a first surface opposite to the opening; a battery assembly housed in the housing; as well as a first cover coupled to the housing and covering the opening, wherein a first side of the battery assembly is coupled to a first side of the first cover, and Wherein, the second side of the battery assembly is spaced apart from the first surface of the housing.

2. The battery pack according to claim 1, wherein: A first side of the battery assembly is attached to a first side of the first cover. 3 . The battery pack according to claim 1 , further comprising a first layer between the battery assembly and the first cover.

4. The battery pack according to claim 1, wherein: The first cover includes a cooling channel between a first side of the first cover and a second side of the first cover, and The first side of the first cover is opposite to the second side of the first cover.

5. The battery pack according to claim 1, wherein: The battery assembly is secured to the first cover and / or the housing.

6. The battery pack according to claim 1, wherein: The housing further includes a sidewall coupled to a first edge of the first surface, wherein the housing includes a mounting portion on the side wall, and Wherein, the battery assembly is coupled to the mounting portion.

7. The battery pack according to claim 6, wherein: The first cover is coupled to the mounting portion.

8. The battery pack according to claim 1, wherein: The housing also includes an exhaust portion.

9. The battery pack according to claim 1, wherein: The housing also includes a support structure on the first surface, and Wherein, the battery assembly is coupled to the support structure.

10. The battery pack according to claim 1, wherein: The battery assembly also includes: A cell assembly, the cell assembly comprising a battery cell; and A bus bar is coupled to the first side of the battery cell assembly.

11. The battery pack according to claim 10, wherein: The battery assembly further includes a second cover, and Wherein, the second cover is connected to the second side of the battery cell assembly.

12. The battery pack according to claim 11, further comprising a first layer, in, The first layer comprises a thermal interface material TIM, wherein the TIM comprises a thermal resin, and Wherein, the first layer is located on the surface of the second cover.

13. The battery pack according to claim 11, wherein: The battery assembly also includes: a third cover coupled to a third side of the battery cell assembly; and A cooling portion is on at least one of the second cover or the third cover.

14. The battery pack according to claim 10, wherein: The battery assembly also includes a second cover coupled to a second side of the cell assembly and a third cover coupled to a third side of the cell assembly.

15. The battery pack according to claim 14, wherein: The second cover has a first shape, and the third cover has a second shape, and Wherein, the first shape and the second shape are configured to correspond to each other for connection.

16. The battery pack according to claim 1, wherein: The battery assembly includes a first battery cell assembly and a second battery cell assembly. Wherein, the first battery cell assembly includes a first bus bar, and the second battery cell assembly includes a second bus bar, and The first battery cell assembly is connected to the second battery cell assembly via the first bus bar and the second bus bar.

17. A vehicle, comprising: A battery pack, the battery pack comprising: a housing comprising an opening and a surface opposite to the opening; a cover configured to cover the opening; a battery assembly coupled to the cover and spaced apart from the surface; and frame, wherein the battery pack is accommodated in the frame, wherein a passenger compartment is above at least a first portion of the battery pack, and Wherein, the frame is below at least a second portion of the battery pack.

18. The battery pack according to claim 10, wherein: The battery assembly further includes a bus bar frame including the bus bar.

19. A battery assembly, comprising: A battery cell assembly, wherein the battery cell assembly includes a battery cell; a first cover coupled to a first side of the battery cell assembly; a second cover coupled to a second side of the battery cell assembly; as well as a layer between the second cover and the second side of the battery cell assembly, wherein the first cover comprises a first cooling portion, and Wherein, the second cover includes a second cooling portion.

20. The battery assembly according to claim 19, wherein: The first cooling portion includes an exhaust opening, and Wherein, the second cooling part includes a cooling channel.

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