Battery module and battery pack including same

Abstract

The technical idea of the present invention provides a battery module, the battery module comprising: a plurality of battery cell assemblies, each comprising a plurality of battery cells; a lower case including a plurality of first pouches spaced apart from each other in the first direction, and a first connection portion extending between two adjacent first pouches among the plurality of first pouches, each of the plurality of first pouch portions has a lower accommodating space for accommodating a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies; and an upper case including a plurality of second pouches spaced apart from each other in the first direction, and a second connection portion between two adjacent second pouches among the plurality of second pouches, each of the plurality of second pouches has an upper accommodation space for accommodating an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies.

Description

Technical Field

[0001] The present invention relates to a battery module and a battery pack including the battery module.

[0002] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0101567, filed on August 3, 2023, and the entire content of the Korean patent application is incorporated herein by reference. Background Art

[0003] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. Secondary batteries have been widely used as an energy source for various types of wireless devices such as mobile phones, laptop computers, and cordless vacuum cleaners. Recently, the main use of secondary batteries is shifting from mobile devices to mobility. Due to the improvement of energy density and economies of scale, the manufacturing cost per unit capacity of secondary batteries has been significantly reduced, and the range of battery electric vehicles (BEVs) has increased to the same level as that of fuel vehicles.

[0004] As secondary batteries are used for mobility, the requirements for the safety of secondary batteries are increasing. When an accident such as a fire occurs in a secondary battery used for mobility, it may endanger the life of the driver, so it is essential to study technologies for improving the safety of secondary batteries. Summary of the Invention

[0005] Technical Problem

[0006] The present invention aims to provide a battery module and a battery pack including the battery module.

[0007] Technical Solution

[0008] One aspect of the present invention provides a battery module, which includes: a plurality of battery cell assemblies, each of the plurality of battery cell assemblies including a plurality of battery cells; a lower housing including a plurality of first pocket portions spaced apart from each other in a first direction and a first connecting portion extending between two adjacent first pocket portions among the plurality of first pocket portions, wherein each of the plurality of first pocket portions includes a lower accommodation space for accommodating a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and the plurality of first pocket portions and the first connecting portion are integrally formed; and an upper housing including a plurality of second pocket portions spaced apart from each other in the first direction and a second connecting portion extending between two adjacent second pocket portions among the plurality of second pocket portions, wherein each of the plurality of second pocket portions includes an upper accommodation space for accommodating an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and the plurality of second pocket portions and the second connecting portion are integrally formed. By coupling the first connecting portion and the second connecting portion, the lower housing and the upper housing are coupled to each other.

[0009] In an exemplary embodiment, the first connecting portion may extend from one end of each of the first pocket portions to the other end of each of the first pocket portions in a second direction intersecting the first direction, and the second connecting portion may extend from one end of each of the second pocket portions to the other end of each of the second pocket portions in the second direction.

[0010] In an exemplary embodiment, the first connecting portion may include a flat upper surface, the second connecting portion may include a flat lower surface, and the upper surface of the first connecting portion may contact the lower surface of the second connecting portion.

[0011] In an exemplary embodiment, the battery module may further include a bonding layer between the first connecting portion and the second connecting portion.

[0012] In an exemplary embodiment, the bonding layer may include metal.

[0013] In an exemplary embodiment, the lower housing may further include a first flange extending from the outermost first pocket portion among the plurality of first pocket portions, the upper housing may further include a second flange extending from the outermost second pocket portion among the plurality of second pocket portions, and the first flange may be coupled to the second flange.

[0014] In an exemplary embodiment, the first flange may extend from one end of the outermost first pocket portion to the other end of the outermost first pocket portion in a second direction that intersects the first direction, the second flange may extend from one end of the outermost second pocket portion to the other end of the outermost second pocket portion in the second direction, the first flange may include a flat upper surface, the second flange may include a flat lower surface, and the upper surface of the first flange may contact the lower surface of the second flange.

[0015] In an exemplary embodiment, the first flange and the second flange may be coupled to each other by a metal bonding layer.

[0016] In an exemplary embodiment, each of the plurality of first pocket portions may include a first cooling channel.

[0017] In an exemplary embodiment, each of the plurality of second pocket portions may include a second cooling channel.

[0018] In an exemplary embodiment, in each of the plurality of battery cell assemblies, the plurality of battery cells may be stacked in the first direction.

[0019] Another aspect of the present invention provides a battery pack, which includes a battery pack housing; and a battery module disposed within the battery pack housing. The battery module includes: a plurality of battery cell assemblies, each of the plurality of battery cell assemblies including a plurality of battery cells; a lower housing including a plurality of first pocket portions spaced apart from each other in a first direction and a first connecting portion extending between two adjacent first pocket portions among the plurality of first pocket portions, wherein each of the plurality of first pocket portions includes a lower accommodation space for accommodating a lower portion of a corresponding one of the plurality of battery cell assemblies, and the plurality of first pocket portions and the first connecting portion are integrally formed; and an upper housing including a plurality of second pocket portions spaced apart from each other in the first direction and a second connecting portion extending between two adjacent second pocket portions among the plurality of second pocket portions, wherein each of the plurality of second pocket portions includes an upper accommodation space for accommodating an upper portion of a corresponding one of the plurality of battery cell assemblies, and the plurality of second pocket portions and the second connecting portion are integrally formed. By coupling the first connecting portion and the second connecting portion, the lower housing and the upper housing are coupled to each other.

[0020] In an exemplary embodiment, the battery module may be spaced apart from the bottom plate of the battery pack housing, and a space may be provided between the battery module and the bottom plate of the battery pack housing.

[0021] In an exemplary embodiment, the battery pack housing may include a support structure configured to support components of the first connection portion and the second connection portion.

[0022] In an exemplary embodiment, the lower housing may further include a first flange extending from the outermost first bag-shaped portion among the plurality of first bag-shaped portions, and the upper housing may further include a second flange extending from the outermost second bag-shaped portion among the plurality of second bag-shaped portions. The first flange may be coupled to the second flange, and the battery pack housing may include a support structure configured to support components of the first flange and the second flange.

[0023] Advantageous Effects

[0024] According to an exemplary embodiment of the present invention, each of the upper housing and the lower housing, as structures for accommodating and supporting a plurality of battery cell components, is configured as an integrated pressing product to simplify the manufacturing process of the battery module and reduce the manufacturing cost of the battery module. The plurality of battery cell components may be accommodated in the accommodation space provided by the upper housing and the lower housing to mass-produce the battery module.

[0025] According to an exemplary embodiment of the present invention, when performing a welding process to join the lower housing and the upper housing, there is a relatively large joining area between the lower housing and the upper housing to ensure a wide weldable area. Thus, the manufacturing process of the battery module can be promoted.

[0026] Furthermore, according to an exemplary embodiment of the present invention, the contact area between the battery module and the support structure of the battery pack housing is relatively large to disperse the stress to be applied to the portions to be fastened of the battery module and the battery pack housing and reduce damage to the portions to be fastened of the battery module and the battery pack housing. Thus, the safety and reliability of the battery pack 500 can be improved.

[0027] The effects achievable from the exemplary embodiments of the present invention are not limited to the above effects, and other effects not described herein will be clearly deduced and understood by those of ordinary skill in the art to which the exemplary embodiments of the present invention pertain from the following description. That is, the unexpected effects obtained when implementing the exemplary embodiments of the present invention can be deduced by those of ordinary skill in the art from the exemplary embodiments of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is an exploded perspective view of a battery module according to an exemplary embodiment of the present invention.

[0029] Figure 2 is a plan view of a battery module according to an exemplary embodiment of the present invention.

[0030] Figure 3 It is a cross-sectional view of a battery module according to an exemplary embodiment of the present invention.

[0031] Figure 4 It is an exploded view of a battery module according to an exemplary embodiment of the present invention.

[0032] Figure 5 It is a cross-sectional view of a joint area between an upper case and a lower case of a battery module according to an embodiment of the present invention.

[0033] Figure 6 It is a cross-sectional view of a battery module according to an exemplary embodiment of the present invention.

[0034] Figure 7 It is a cross-sectional view of a battery pack according to an exemplary embodiment of the present invention.

[0035] Figure 8 It is a schematic view of an electric vehicle in which a battery pack according to an exemplary embodiment of the present invention is installed. Detailed Embodiments

[0036] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Before describing the embodiments of the present invention, the terms or expressions used in this specification and the claims should not be construed as limited to those commonly understood or defined in a common dictionary, and should be understood based on the principle that the inventors of this application can appropriately define the terms or expressions to best explain the present invention, according to the meanings and concepts corresponding to the present invention.

[0037] Therefore, the embodiments described herein and the configurations shown in the drawings are only examples of the present invention and do not reflect all the technical concepts of the present invention. Therefore, it should be understood that various equivalents and modifications of these configurations have been made as of the filing date of this application.

[0038] When it is determined that known configurations or functions related to the description of the present invention obscure the subject matter of the present invention due to unnecessary details, they will not be described in detail.

[0039] Since the embodiments of the present invention are provided to more fully explain the present invention to those of ordinary skill in the art, the shapes, sizes, etc. of the components shown in the drawings may be exaggerated, omitted, or schematically illustrated for clarity. Therefore, it should not be understood that the dimensions or ratios of the components completely reflect their actual dimensions or ratios.

[0040] (First Embodiment)

[0041] Figures 1 to 5 It is a view showing a battery module 10 according to an exemplary embodiment of the present invention. Figure 1is an exploded perspective view of the battery module 10. Figure 2 is a plan view of the battery module 10. Figure 3 is a cross-sectional view of the battery module 10. Figure 4 is an exploded view of the battery module 10. Figure 5 is a cross-sectional view of a joint area between the upper case 300 and the lower case 200 of the battery module 10.

[0042] Referring to Figures 1 to 5 , the battery module 10 may include a plurality of battery cell assemblies 100, a lower case 200, and an upper case 300.

[0043] The plurality of battery cell assemblies 100 may be arranged in a first direction (X-axis direction). The plurality of battery cell assemblies 100 may be spaced apart from each other in the first direction (X-axis direction). Although an example is shown in which the battery module 10 includes two battery cell assemblies 100, the number of battery cell assemblies 100 included in the battery module 10 is not limited to two. For example, the battery module 10 may include two or more battery cell assemblies 100.

[0044] Each of the battery cell assemblies 100 may include a cell block 110. The cell block 110 may include a plurality of battery cells 111. Each of the battery cells 111 is a basic unit of a lithium-ion battery, i.e., a secondary battery. Each of the battery cells 111 may include an electrode assembly, an electrolyte, and a cell case. The electrode assembly disposed in the cell case may include a positive electrode, a negative electrode, and a separator located between the positive electrode and the negative electrode. Depending on the assembly form, the electrode assembly may be a wound-core type electrode assembly or a stacked type electrode assembly. The wound-core type electrode assembly may include a structure in which the positive electrode, the negative electrode, and the separator between the positive electrode and the negative electrode are wound together. The stacked type electrode assembly may include a plurality of positive electrodes and a plurality of negative electrodes stacked in sequence, and a plurality of separators between the plurality of positive electrodes and the plurality of negative electrodes. The positive electrode may include a positive electrode current collector and a positive electrode active material. The negative electrode may include a negative electrode current collector and a negative electrode active material.

[0045] The plurality of battery cells 111 may be connected in series or in parallel. For example, the plurality of battery cells 111 may be connected in series with each other. For example, the plurality of battery cells 111 may be connected in parallel with each other. For example, when a group of two or more battery cells 111 connected in parallel is defined as a bank, one bank including two or more battery cells 111 connected in parallel and another bank including two or more battery cells 111 connected in parallel may be connected in series.

[0046] Each of the battery cells 111 can be a pouch-type battery cell, a cylindrical battery cell, or a prismatic battery cell. The electrode assembly of the pouch-type battery cell is embedded in a pouch-type housing including an aluminum laminate. The electrode assembly of the cylindrical battery cell is embedded in a cylindrical metal can. The electrode assembly of the prismatic battery cell is embedded in a prismatic metal can.

[0047] In an exemplary embodiment, the battery cells 111 can be pouch-type battery cells and are stacked together in a battery cell assembly 100 in a first direction (X-axis direction). In an exemplary embodiment, in each battery cell assembly 100, the plurality of battery cells 111 can be pouch-type battery cells whose length in the first direction (X-axis direction) is less than its length in a second direction (Y-axis direction) and are stacked in the first direction (X-axis direction).

[0048] When viewed in a plan view, the cell block 110 can have a rectangular shape whose length in the first direction (X-axis direction) is less than its length in the second direction (Y-axis direction). The cell block 110 can have a first side surface and a second side surface facing each other in the first direction (X-axis direction), a front surface and a rear surface facing each other in the second direction (Y-axis direction), and an upper surface and a lower surface facing each other in a third direction (Z-axis direction).

[0049] On each of the front surface and the rear surface of the cell block 110, there can be a bus bar frame on which a bus bar is mounted. A plurality of bus bars can be mounted on the bus bar frame on the front surface of the cell block 110, and a plurality of bus bars can be mounted on the bus bar frame on the rear surface of the cell block 110. The battery cell assembly 100 can include an end plate 120 to cover the bus bar frame connected to the front surface or the rear surface of the cell block 110.

[0050] The bus bar can be coupled to the electrode lead of the battery cell 111. For example, the bus bar can be coupled to the electrode lead of the battery cell 111 by welding. For example, each bus bar can be an inter-bus bar that is coupled to the electrode leads of different battery cells 111 belonging to the cell block 110 to electrically connect the different battery cells 111. For example, each bus bar can be a terminal bus bar for electrically coupling the battery cell assembly 100 to another external battery cell assembly 100 or another electrical device.

[0051] The battery cell assembly 100 can include a plurality of cell blocks 110. For example, as Figure 1 shown, each of the battery cell assemblies 100 can include two cell blocks 110 arranged to be electrically connected to each other in the second direction (Y-axis direction).

[0052] The lower housing 200 may support a plurality of battery cell assemblies 100. The lower housing 200 may include a plurality of lower accommodation spaces 220 for accommodating the plurality of battery cell assemblies 100. Each of the lower accommodation spaces 220 may accommodate a lower portion of a corresponding one of the plurality of battery cell assemblies 100. The number of the lower accommodation spaces 220 of the lower housing 200 may be the same as the number of the battery cell assemblies 100. In an exemplary embodiment, the lower housing 200 may be a one-piece unit, and its overall material composition may be the same. For example, to manufacture the lower housing 200, a single flat plate may be prepared, and pressing may be performed on the single flat plate to make the single flat plate have a predetermined structure.

[0053] The lower housing 200 may include a plurality of first bag-shaped portions 210, a first connection portion 230, and a first flange 240. The plurality of first bag-shaped portions 210, the first connection portion 230, and the first flange 240 may be formed integrally.

[0054] The plurality of first bag-shaped portions 210 may be spaced apart from each other in a first direction (X-axis direction). Each of the first bag-shaped portions 210 may include a lower accommodation space 220 for accommodating a lower portion of a corresponding battery cell assembly 100. When viewed in a cross-sectional view, each of the first bag-shaped portions 210 may have a U shape. Each of the first bag-shaped portions 210 may include a bottom wall facing the lower surface of a corresponding battery cell assembly 100, and two lower side walls spaced apart from each other in the first direction (X-axis direction), with the corresponding battery cell assembly 100 located between the two lower side walls. One of the two lower side walls may continuously extend along a first edge of the bottom wall, and the other lower side wall may continuously extend along a second edge opposite to the first edge of the bottom wall. When viewed in a plan view, the bottom wall may have a quadrilateral shape. In each of the first bag-shaped portions 210, the lower accommodation space 220 may be defined by the bottom wall and the two lower side walls. The length of the lower accommodation space 220 in the first direction (X-axis direction) may be equal to the length of the bottom wall in the first direction (X-axis direction), the length of the lower accommodation space 220 in a second direction (Y-axis direction) may be equal to the length of the bottom wall in the second direction (Y-axis direction), and the length (or depth) of the lower accommodation space 220 in a third direction (Z-axis direction) may be equal to the length of the lower side wall in the third direction (Z-axis direction).

[0055] The first connecting portion 230 can extend between two first pocket portions 210 that are adjacent to each other among the plurality of first pocket portions 210 along the first direction (X-axis direction). For example, the first connecting portion 230 can extend from the upper end of one first pocket portion 210 among the two first pocket portions 210 to the upper end of the other second pocket portion 310 to physically connect the two first pocket portions 210. The first connecting portion 230 can have a quadrilateral flat plate shape. The first connecting portion 230 can have a quadrilateral shape when viewed in a plan view, and the upper surface of the first connecting portion 230 can be flat. The first connecting portion 230 can continuously extend from one end of the first pocket portion 210 to the other end of the first pocket portion 210 in the second direction (Y-axis direction), and the length of the first connecting portion 230 in the second direction (Y-axis direction) can be the same as or substantially the same as the length of the first pocket portion 210 in the second direction (Y-axis direction).

[0056] The first flange 240 can be connected to the outermost first pocket portion 210 among the plurality of first pocket portions 210. For example, the lower housing 200 can include one first flange 240 that extends outward from the leftmost first pocket portion 210 among the plurality of first pocket portions 210, and one first flange 240 that extends outward from the rightmost first pocket portion 210 among the plurality of first pocket portions 210. The first flange 240 can continuously extend along the edge of the corresponding first pocket portion 210 in the second direction (Y-axis direction). The first flange 240 can have a quadrilateral flat plate shape. The first flange 240 can have a quadrilateral shape when viewed in a plan view, and the upper surface of the first flange 240 can be flat. The first flange 240 can continuously extend from one end of the first pocket portion 210 to the other end of the first pocket portion 210 in the second direction (Y-axis direction), and the length of the first flange 240 in the second direction (Y-axis direction) can be the same as or substantially the same as the length of the first flange 240 in the second direction (Y-axis direction).

[0057] The upper housing 300 may be located on the lower housing 200. The upper housing 300 may be coupled to the lower housing 200 to cover a plurality of battery cell assemblies 100 on the lower housing 200. The upper housing 300 may include a plurality of upper accommodation spaces 320 for accommodating the plurality of battery cell assemblies 100. Each of the upper accommodation spaces 320 may accommodate an upper portion of a corresponding one of the plurality of battery cell assemblies 100. The number of the upper accommodation spaces 320 of the upper housing 300 may be the same as the number of the battery cell assemblies 100, and the position of each of the upper accommodation spaces 320 may vertically overlap a corresponding one of the plurality of lower accommodation spaces 220. In an exemplary embodiment, the upper housing 300 may be a single-piece and its overall material composition may be the same. For example, to manufacture the upper housing 300, a single flat plate may be prepared and pressing may be performed on the single flat plate to make the single flat plate have a predetermined structure.

[0058] The upper housing 300 may include a plurality of second bag-like portions 310, second connection portions 330, and second flanges 340. The plurality of second bag-like portions 310, second connection portions 330, and second flanges 340 may be formed integrally.

[0059] The plurality of second bag-like portions 310 may be spaced apart from each other in a first direction (X-axis direction). Each of the second bag-like portions 310 may include an upper accommodation space 320 for accommodating an upper portion of a corresponding battery cell assembly 100. Each of the second bag-like portions 310 may include an upper wall facing an upper surface of a corresponding battery cell assembly 100, and two upper side walls spaced apart from each other in the first direction (X-axis direction), with the corresponding battery cell assembly 100 located between the two upper side walls. One of the two upper side walls may continuously extend along a first edge of the upper wall, and the other upper side wall may continuously extend along a second edge opposite to the first edge of the upper wall. When viewed in a plan view, the upper wall may have a quadrilateral shape. In each of the second bag-like portions 310, the upper accommodation space 320 may be defined by the upper wall and the two upper side walls. The length of the upper accommodation space 320 in the first direction (X-axis direction) may be equal to the length of the upper wall in the first direction (X-axis direction), the length of the upper accommodation space 320 in the second direction (Y-axis direction) may be equal to the length of the upper wall in the second direction (Y-axis direction), and the length (or depth) of the upper accommodation space 320 in the third direction (Z-axis direction) may be equal to the length of the upper side wall in the third direction (Z-axis direction).

[0060] The second connecting part 330 can extend between two second pocket parts 310 that are adjacent to each other in the first direction (X-axis direction) among the plurality of second pocket parts 310. For example, the second connecting part 330 can extend from the lower end of one of the two second pocket parts 310 to the lower end of the other second pocket part 310 to physically connect the two second pocket parts 310. The second connecting part 330 can have a quadrilateral flat plate shape. The second connecting part 330 can have a quadrilateral shape when viewed in a plan view, and the lower surface of the second connecting part 330 can be flat. The second connecting part 330 can continuously extend from one end of the second pocket part 310 to the other end of the second pocket part 310 in the second direction (Y-axis direction), and the length of the second connecting part 330 in the second direction (Y-axis direction) can be the same as or substantially the same as the length of the second pocket part 310 in the second direction (Y-axis direction). The lower surface of the second connecting part 330 can be in surface contact with the upper surface of the first connecting part 230. The first connecting part 230 and the first connecting part 230 can be in contact with each other continuously or discontinuously in the second direction (Y-axis direction). The second connecting part 330 can be coupled to the first connecting part 230. The second connecting part 330 can be coupled to the first connecting part 230 to couple the upper housing 300 to the lower housing 200.

[0061] The second flange 340 can be connected to the outermost second pocket part 310 among the plurality of second pocket parts 310. For example, the upper housing 300 can include one second flange 340 that extends outward from the leftmost second pocket part 310 among the plurality of second pocket parts 310, and one second flange 340 that extends outward from the rightmost second pocket part 310 among the plurality of second pocket parts 310. The second flange 340 can continuously extend along the edge of the corresponding second pocket part 310 in the second direction (Y-axis direction). The second flange 340 can have a quadrilateral flat plate shape. The second flange 340 can have a quadrilateral shape when viewed in a plan view, and the lower surface of the second flange 340 can be flat. The second flange 340 can continuously extend from one end of the second pocket part 310 to the other end of the second pocket part 310 in the second direction (Y-axis direction), and the length of the second flange 340 in the second direction (Y-axis direction) can be the same as or substantially the same as the length of the second pocket part 310 in the second direction (Y-axis direction). The second flange 340 and the first flange 240 can be in contact with each other continuously or discontinuously in the second direction (Y-axis direction). The lower surface of the second flange 340 can be in surface contact with the upper surface of the first flange 240. The second flange 340 can be coupled to the first flange 240. The second flange 340 can be coupled to the first flange 240 to couple the upper housing 300 to the lower housing 200.

[0062] In an exemplary embodiment, the lower housing 200 and the upper housing 300 may be joined to each other by welding. As Figure 5 shown, a bonding layer 410, such as a metal bonding layer containing metal, may be interposed between the lower housing 200 and the upper housing 300. The metal bonding layer may be a material layer formed by welding. In an exemplary embodiment, the bonding layer 410 may be interposed between the upper surface of the first connection portion 230 of the lower housing 200 and the lower surface of the second connection portion 330 of the upper housing 300, and the first connection portion 230 may be joined to the second connection portion 330 through the bonding layer 410. At the interface between the first connection portion 230 and the second connection portion 330, the bonding layer 410 may extend continuously or discontinuously in the second direction (Y-axis direction). In an exemplary embodiment, the bonding layer 410 may be interposed between the upper surface of the first flange 240 of the lower housing 200 and the lower surface of the second flange 340 of the upper housing 300, and the first flange 240 may be joined to the second flange 340 through the bonding layer 410. At the interface between the first flange 240 and the second flange 340, the bonding layer 410 may extend continuously or discontinuously in the second direction (Y-axis direction).

[0063] In an exemplary embodiment, the upper housing 300 may include a cooling channel 311 configured to allow a coolant to flow therethrough, and may be configured to cool the battery cell assembly 100 such that the battery cell assembly 100 may have an appropriate operating temperature. The cooling channel 311 may be provided in each of a plurality of second pocket portions 310 of the upper housing 300. For example, the cooling channel 311 may be provided in the upper wall and / or upper side wall of each of the second pocket portions 310. The coolant supplied from the outside may flow into the cooling channel 311 through the inlet of the cooling channel 311, flow along the cooling channel 311, and be discharged to the outside through the outlet of the cooling channel 311. When the coolant flows along the cooling channel 311, the battery cell assembly 100 may be cooled. In an exemplary embodiment, a thermally conductive adhesive layer may be interposed between the upper housing 300 and the battery cell assembly 100 to improve the thermal connection between the upper housing 300 and the battery cell assembly 100. The thermally conductive adhesive layer may include, for example, a thermal interface material (TIM). In this case, the heat generated in the battery cell assembly 100 may be transferred to the upper housing 300 through the thermally conductive adhesive layer.

[0064] According to an exemplary embodiment of the present invention, each of the upper housing 300 and the lower housing 200, as a structure for accommodating and supporting a plurality of battery cell assemblies 100, is configured as an integrated pressing product to simplify the manufacturing process of the battery module 10 and reduce the manufacturing cost of the battery module 10. Since a plurality of battery cell assemblies 100 may be accommodated in the accommodation space provided by the upper housing 300 and the lower housing 200, the battery module 10 may be mass-produced.

[0065] In addition, according to an exemplary embodiment of the present invention, the joint area between the lower housing 200 and the upper housing 300 is relatively large. Therefore, when performing a welding process to couple the lower housing 200 and the upper housing 300, a relatively wide weldable area can be ensured. Accordingly, the manufacturing process of the battery module 10 can be facilitated.

[0066] (Second Embodiment)

[0067] Figure 6 is a cross-sectional view of a battery module 10A according to an exemplary embodiment of the present invention. Hereinafter, the Figure 6 battery module 10A will be mainly described with respect to the differences from the battery module 10 described above with reference to Figures 1 to 5 description.

[0068] Referring to Figure 6 , in the battery module 10A, the lower housing 200 may include a cooling channel 211 configured to allow a coolant to flow therethrough and may be configured to cool the battery cell assembly 100 so that the battery cell assembly 100 can have an appropriate operating temperature. The cooling channel 211 may be provided in each of a plurality of first pocket portions 210 of the lower housing 200. For example, the cooling channel 211 may be provided in the lower wall and / or the lower sidewall of each of the first pocket portions 210. The coolant provided from the outside may flow into the cooling channel 211 through an inlet of the cooling channel 211, flow along the cooling channel 211, and be discharged to the outside through an outlet of the cooling channel 211. In an exemplary embodiment, a thermally conductive adhesive layer including a material such as TIM may be interposed between the lower housing 200 and the battery cell assembly 100 to improve the thermal connection between the lower housing 200 and the battery cell assembly 100.

[0069] In an exemplary embodiment, both the upper housing 300 and the lower housing 200 may include the cooling channel 211. That is, the upper housing 300 may include a cooling channel 311 as shown in Figure 3 , and the lower housing 200 may include a cooling channel 211 as shown in Figure 6 .

[0070] (Third Embodiment)

[0071] Figure 7 is a cross-sectional view of a battery pack 500 according to an exemplary embodiment of the present invention.

[0072] Referring to Figure 7 , the battery pack 500 may include a battery pack housing 501 and a battery module 10 disposed on the battery pack housing 501. The battery pack 500 may include one or more battery modules 10 on the battery pack housing 501. AlthoughFigure 7 shows that the battery pack 500 includes the battery module 10 described above with reference to Figures 1 to 5 but the embodiment is not limited thereto, and the battery pack 500 may include the battery module 10A described above with reference to Figure 6 the description.

[0073] The battery pack housing 501 may include a lower housing 510 having an accommodation space for accommodating the battery module 10, and a battery pack cover 520 coupled to the lower housing 510 to cover the lower housing 510 in which the battery module 10 is accommodated. The accommodation space of the lower housing 510 may be defined by a bottom plate 511 facing the lower surface of the battery module 10 and side walls 513 located at the edges of the bottom plate 511. A plurality of support structures 515 may be provided on the bottom plate 511 of the lower housing 510 to support the battery module 10. The plurality of support structures 515 may be spaced apart from each other in a first direction (X-axis direction) and each extend in a second direction (Y-axis direction). The length of each of the support structures 515 in the second direction (Y-axis direction) may be equal to or greater than the length of the battery module 10 in the second direction (Y-axis direction).

[0074] The battery module 10 may be mounted in the battery pack housing 501 in a side-mounted manner. A plurality of support structures 515 each extending in the second direction (Y-axis direction) may be provided on the bottom plate 511 of the battery pack housing 501, and the battery module 10 may be fastened to the plurality of support structures 515 by fasteners such as bolts BT.

[0075] More specifically, the first connection portion 230 of the lower housing 200 and the second connection portion 330 of the upper housing 300 may be combined to form a first assembly, and the first assembly may be disposed on a corresponding one of the plurality of support structures 515 and fastened to the corresponding support structure 515 by bolts BT. The support structure 515 may be in continuous contact with the first assembly in the second direction (Y-axis direction). Since the contact area between the support structure 515 and the first assembly may be relatively large, the battery module 10 may be stably supported by the support structure 515.

[0076] In addition, the first flange 240 of the lower housing 200 and the second flange 340 of the upper housing 300 may be combined to form a second assembly, and the second assembly may be disposed on a corresponding one of the plurality of support structures 515 and fastened to the corresponding support structure 515 by bolts BT. The support structure 515 may be in continuous contact with the second assembly in the second direction (Y-axis direction). Since the contact area between the support structure 515 and the second assembly may be relatively large, the battery module 10 may be stably supported by the support structure 515.

[0077] When the battery pack 500 is installed in a vehicle, the passenger compartment where passengers sit can be located above the battery pack cover 520, and the ground on which the vehicle travels can be located below the lower housing 510.

[0078] The battery module 10 can be supported on the bottom plate 511 of the lower housing 510 by a support structure 515 in a side-mounted manner, and when the bottom plate 511 of the lower housing 510 and the battery module 10 are spaced apart from each other in the third direction (Z-axis direction), a free volume FV can be formed between the bottom plate 511 of the lower housing 510 and the battery module 10. The gas and flame generated in the case of thermal runaway can move through the free volume FV. That is, the free volume FV serves as an exhaust passage through which the high-temperature gas and flame can move.

[0079] Even when a strong impact is generated due to foreign substances splashing onto the lower part of the vehicle while driving on a hard ground such as an unpaved road, the impact can be absorbed through the free volume FV. Therefore, the battery module 10 can be prevented from being damaged due to the impact. The free volume FV can be understood as the blank space between the battery module 10 and the lower housing 510. When the lower housing 510 deforms toward the battery module 10 due to the impact applied to the lower part of the vehicle, the free volume FV can freely allow the deformation of the lower housing 510 to a certain extent.

[0080] The height of the free volume FV and the distance between the bottom plate 511 of the lower housing 510 and the battery module 10 can be determined to be sufficient to absorb external impacts. The height of the free volume FV can be determined by considering the dimensions and stiffness of the vehicle frame, the dimensions and stiffness of the lower housing 510, the dimensions of the battery pack 500, the amount of gas generated during thermal runaway, and the gas discharge rate, etc. For example, when the thickness or stiffness of the vehicle frame or the bottom plate 511 of the lower housing 510 is relatively large, at least one of the dimensions and height of the free volume FV can be relatively reduced. When the thickness or stiffness of the vehicle frame or the bottom plate 511 of the lower housing 510 is relatively small, the bottom plate 511 of the lower housing 510 is extremely likely to deform, so at least one of the dimensions and height of the free volume FV can be relatively increased to protect the battery module 10. When the dimensions of the battery pack 500 are relatively large compared to the specifications of the battery pack 500, a relatively large free volume FV can be ensured. When the dimensions of the battery pack 500 are relatively small, the height of the free volume FV to be ensured can be relatively small, so that the thickness and stiffness of the bottom plate 511 of the lower housing 510 can be relatively increased. When the height of the free volume FV is extremely small, the gas discharge passage can be small, so the internal pressure of the battery pack 500 may increase sharply during thermal runaway. Therefore, the dimensions and height of the free volume FV can be determined by considering the amount of gas generated and the gas discharge rate.

[0081] The maximum height of the free volume FV can be determined according to the damage tolerance of the battery cells 111 included in the battery module 10. For example, when the damage tolerance of the battery cell 111 is 1 mm, the free volume FV can be determined to prevent the battery cell 111 from deforming by more than 1 mm when the lower housing 510 deforms and presses the lower surface of the battery cell 111. In this case, the degree of deformation of the lower housing 510 may vary according to the thickness or stiffness of the lower housing 510. Therefore, the size or height of the free volume FV can be determined by considering all the damage tolerances of the battery cells 111 and the thickness and rigidity of the lower housing 510.

[0082] In an exemplary embodiment, the upper surface of the battery module 10 may be in close contact with the lower side of the battery pack cover 520. In an exemplary embodiment, the battery module 10 may be supported while being suspended on the battery pack cover 520. When there is a space between the battery module 10 and the battery pack cover 520, during thermal runaway, high-temperature gas may flow into the space between one of the battery modules 10 and the battery pack cover 520, and heat and flames may spread to adjacent battery modules 10 and be transferred to the battery pack cover 520. Therefore, the compartment above the battery pack cover 520 may be affected by heat and flames. Therefore, by bringing the upper surface of the battery module 10 into close contact with the lower surface of the battery pack cover 520, the gas or flames generated in the battery pack 500 can be guided to the free volume FV.

[0083] According to an exemplary embodiment of the present invention, the contact area between the battery module 10 and the support structure 515 of the battery pack housing 501 is relatively large to disperse the stress applied to the connection portion between the battery module 10 and the battery pack housing 501 and reduce damage to the connection portion between the battery module 10 and the battery pack housing 501. Therefore, the safety and reliability of the battery pack 500 can be improved.

[0084] (Fourth Embodiment)

[0085] Figure 8 is a schematic view of an electric vehicle 1000 in which a battery pack 1100 according to an exemplary embodiment of the present invention is installed.

[0086] For simplicity, Figure 8 only the body frame 1200 forming the lower frame of the electric vehicle 1000, and the battery pack 1100 and tires coupled to the body frame 1200 are shown. The battery pack 1100 may include the battery pack 500 described above with reference to Figure 7 description.

[0087] In the case of a general battery pack, the battery modules are installed at the bottom of the battery pack housing. In an embodiment, a free volume FV may be provided below the battery module 10 of the battery pack 1100 (seeFigure 7 ) and there may be no space or a very narrow space between the battery module 10 and the battery pack cover 520. Accordingly, gas generated in the battery module 10 can be prevented from being transferred to the compartment corresponding to the upper part of the vehicle, and can be guided to the free volume FV between the battery module 10 and the battery pack housing 501 of the battery pack 1100. The gas can flow through the free volume FV to be discharged to the lower side of the electric vehicle 1000 through a gas discharge port installed in the battery pack 1100. In addition, according to the present embodiment, in the battery pack 1100, the free volume FV is provided between the battery module 10 and the battery pack housing, so that even if the battery pack housing 501 is deformed, the battery module 10 can be prevented from being damaged.

[0088] According to an embodiment of the present invention, the battery pack 1100 and the electric vehicle 1000 including the battery pack 1100 can improve the safety of passengers. In addition, the battery module 10, which is a key component, can be protected, and the durability of the battery pack 1100 and the electric vehicle 1000 can be enhanced.

[0089] The present invention has been described in more detail above with reference to the drawings, embodiments, etc. However, the configurations shown in the drawings or the embodiments described in this specification are only embodiments of the present invention and do not reflect all the technical concepts of the present invention. Therefore, it should be understood that various equivalents and modifications substituting these configurations have been made as of the filing date of the present application.

Claims

1. A battery module, comprising: a plurality of battery cell assemblies, each of the plurality of battery cell assemblies comprising a plurality of battery cells; a lower shell, the lower shell comprising a plurality of first pockets spaced apart from each other in a first direction, and a first connecting portion extending between two adjacent first pockets among the plurality of first pockets, wherein each of the plurality of first pockets comprises a lower accommodating space for accommodating a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and the plurality of first pockets and the first connecting portion are integrally formed; and an upper shell, the upper shell comprising a plurality of second pockets spaced apart from each other in the first direction, and a second connecting portion extending between two adjacent second pockets among the plurality of second pockets, wherein each of the plurality of second pockets comprises an upper accommodating space for accommodating an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and the plurality of second pockets and the second connecting portion are integrally formed, Wherein, the lower shell and the upper shell are coupled to each other by coupling the first connection portion and the second connection portion.

2. The battery module according to claim 1, wherein: The first connection portion extends from one end of each of the first pocket-shaped portions to the other end of each of the first pocket-shaped portions along a second direction intersecting the first direction, and The second connection portion extends from one end of each of the second pocket-shaped portions to the other end of each of the second pocket-shaped portions along the second direction.

3. The battery module according to claim 2, wherein: The first connecting portion comprises a flat upper surface, The second connecting portion includes a flat lower surface, and An upper surface of the first connection portion contacts a lower surface of the second connection portion.

4. The battery module according to claim 1, further comprising: A bonding layer is provided between the first connection portion and the second connection portion.

5. The battery module according to claim 4, wherein: The bonding layer includes metal.

6. The battery module according to claim 1, wherein: The lower shell further includes a first flange extending from an outermost first pocket among the plurality of first pockets. The upper shell further includes a second flange extending from an outermost second pocket among the plurality of second pockets, and The first flange is coupled to the second flange.

7. The battery module according to claim 6, wherein: The first flange extends from one end of the outermost first bag-shaped portion to the other end of the outermost first bag-shaped portion along a second direction intersecting the first direction, The second flange extends from one end of the outermost second pocket-shaped portion to the other end of the outermost second pocket-shaped portion along the second direction, The first flange comprises a flat upper surface, The second flange includes a flat lower surface, and An upper surface of the first flange contacts a lower surface of the second flange.

8. The battery module according to claim 6, wherein: The first flange and the second flange are coupled to each other by a metal bonding layer.

9. The battery module according to claim 1, wherein: Each of the plurality of first pockets includes a first cooling channel.

10. The battery module according to claim 1, wherein: Each of the plurality of second pockets includes a second cooling channel.

11. The battery module according to claim 1, wherein: In each of the plurality of battery cell assemblies, the plurality of battery cells are stacked in the first direction.

12. A battery pack, comprising: Battery pack housing; as well as a battery module, the battery module being in the battery pack housing, Wherein, the battery module comprises: a plurality of battery cell assemblies, each of the plurality of battery cell assemblies comprising a plurality of battery cells; a lower shell, the lower shell comprising a plurality of first pockets spaced apart from each other in a first direction, and a first connecting portion extending between two adjacent first pockets among the plurality of first pockets, wherein each of the plurality of first pockets comprises a lower accommodating space for accommodating a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and the plurality of first pockets and the first connecting portion are integrally formed; and an upper shell, the upper shell comprising a plurality of second pockets spaced apart from each other in the first direction, and a second connecting portion extending between two adjacent second pockets among the plurality of second pockets, wherein each of the plurality of second pockets comprises an upper accommodating space for accommodating an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and the plurality of second pockets and the second connecting portion are integrally formed, Wherein, the lower shell and the upper shell are coupled to each other by coupling the first connection portion and the second connection portion.

13. The battery pack according to claim 12, wherein: The battery module is spaced apart from a bottom plate of the battery pack housing, and A space is provided between the battery module and a bottom plate of the battery pack housing.

14. The battery pack according to claim 12, wherein: The battery pack housing includes a support structure configured to support an assembly of the first connection portion and the second connection portion.

15. The battery pack according to claim 12, wherein: The lower shell further includes a first flange extending from an outermost first pocket among the plurality of first pockets. The upper shell further includes a second flange extending from an outermost second pocket among the plurality of second pockets. The first flange is coupled to the second flange, and The battery pack housing includes a support structure configured to support an assembly of the first flange and the second flange.

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