Battery module, side cover of battery module, and method for manufacturing side cover of battery module

Abstract

Provided are a battery module, a side cover of the battery module, and a method of manufacturing the side cover of the battery module, the battery module including: a cell stack including a plurality of battery cells stacked in one direction; and side covers on opposite sides of the cell stack, in which each of the side covers includes: a plate-shaped side plate including a plurality of coupling holes; and an insulating molding including a coupling portion filling the plurality of coupling holes.

Description

Technical Field

[0001] Aspects of some embodiments of the present disclosure relate to a battery module, a side cover of the battery module, and a method of manufacturing the side cover. Background Art

[0002] Unlike primary batteries, which are not designed to be (re)charged, secondary (or rechargeable) batteries are batteries designed to be discharged and recharged. Low-capacity secondary batteries are used in portable small electronic devices such as smart phones, feature phones, notebook computers, digital cameras, and video cameras, while large-capacity secondary batteries are widely used as power sources for driving motors in hybrid vehicles and electric vehicles and for storing electricity (e.g., home and / or utility-scale power storage). Secondary batteries generally include an electrode assembly consisting of a positive electrode and a negative electrode, a housing that accommodates the electrode assembly, and electrode terminals connected to the electrode assembly.

[0003] The above information disclosed in this background section is only for enhancement of understanding of the background technology and therefore, the information discussed in this background section does not necessarily constitute prior art. Summary of the invention

[0004] Aspects of some embodiments of the present disclosure include a battery module, a side cover of the battery module, and a method of manufacturing the side cover.

[0005] These and other aspects and features according to embodiments of the present disclosure will be described in or will be apparent from the following description of embodiments of the present disclosure.

[0006] A battery module according to some embodiments of the present disclosure may include: a cell stack including a plurality of battery cells stacked in one direction; and a side cover disposed on opposite sides of the cell stack, wherein each of the side covers may include: a plate-shaped side plate including a plurality of coupling holes; and an insulating molded part including a coupling portion filling the coupling holes.

[0007] According to some embodiments of the present disclosure, the insulation molding may be integrally provided with the side plate by insert injection.

[0008] According to some embodiments of the present disclosure, the insulation molding may include a plate-shaped body covering at least a portion of a first surface of the side plate facing the unit stack, and the coupling portion may include a plurality of coupling protrusions integrally provided with the plate-shaped body.

[0009] According to some embodiments of the present disclosure, the side plate may include a recessed portion provided in at least a portion of the first surface and recessed toward a second surface opposite to the first surface, and the plate-shaped body of the insulation molding may cover the recessed portion of the side plate.

[0010] According to some embodiments of the present disclosure, the insulation molding may include a plate-shaped first plate covering at least a portion of a first surface of the side plate facing the unit stack and a plate-shaped second plate covering at least a portion of a second surface of the side plate opposite to the first surface.

[0011] According to some embodiments of the present disclosure, the combining portion is integrally provided with the first plate and the second plate, and may include a plurality of combining columns connecting the first plate and the second plate.

[0012] According to some embodiments of the present disclosure, the side plate may include a recessed portion provided in at least a portion of the first surface and recessed toward the second surface, and the first plate of the insulation molding covers the recessed portion of the side plate.

[0013] According to some embodiments of the present disclosure, each of the battery cells may include a prismatic battery cell.

[0014] According to some embodiments of the present disclosure, the battery module may further include: a pair of end plates supporting the outermost surfaces of the cell stack in the one direction; and an end insulating cover disposed between the cell stack and the end plates.

[0015] A side cover of a battery module according to some embodiments of the present disclosure may include: a plate-shaped side plate including a plurality of coupling holes; and an insulating molded member including coupling portions filling the coupling holes.

[0016] According to some embodiments of the present disclosure, the method for manufacturing the side cover of a battery module may include the following steps: placing a plate-shaped side panel including a plurality of coupling holes in an injection mold; injecting molten resin into a cavity inside the injection mold in which the side panel is placed; cooling the molten resin to form an insulating molded part including a coupling portion filling the coupling holes; and removing the integrated side cover including the side panel and the insulating molded part from the inside of the injection mold.

[0017] According to some embodiments of the present disclosure, the side panel may include a recessed portion provided in at least a portion of the first surface and recessed toward a second surface opposite to the first surface, and the cavity into which the molten resin is injected may be the recessed portion of the side panel.

[0018] According to some embodiments of the present disclosure, a cavity into which the molten resin is injected may be provided on a first surface of the side plate and a second surface opposite to the first surface.

[0019] According to some embodiments of the present disclosure, placing the side panel in the injection mold may include positioning the side panel in a lower mold of the injection mold and fitting an upper mold of the injection mold to the lower mold.

[0020] However, characteristics according to the embodiments of the present disclosure are not limited to the above problems, and those skilled in the art will clearly understand other problems not mentioned herein and aspects and features of the present disclosure to solve these problems through the following description of the present disclosure.

[0021] According to some embodiments of the present disclosure, the strength of the battery module may be increased, and an excellent insulation effect may be expected.

[0022] According to some embodiments of the present disclosure, in response to manufacturing the insulation molded part by injection molding at a relatively low temperature, the heat damage applied to the side plate according to the insulation paper attachment method by heat melting can be reduced. Therefore, the defect rate due to warping of the side plate, etc. can be reduced. In addition, the reduced cooling time can reduce the production cycle time, which can improve productivity.

[0023] According to some embodiments of the present disclosure, the insulation molding manufactured to cover the opposite surfaces of the side plate may not only perform the function of insulating the side plate and the cell stack from each other but also perform the function of preventing or reducing heat transfer to adjacent modules.

[0024] However, aspects and features according to the embodiments of the present disclosure are not limited to the aspects and features described above, and other aspects and features not mentioned will be clearly understood by those skilled in the art through the detailed description described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings attached to this specification illustrate embodiments of the present disclosure, and together with the detailed description of the present disclosure, further describe aspects and features of the present disclosure. Therefore, the present disclosure should not be interpreted as being limited to the accompanying drawings.

[0026] Figure 1 A perspective view showing an example of a battery cell according to some embodiments of the present disclosure is shown.

[0027] Figure 2 An exploded perspective view showing an example of exploded parts of a battery module according to some embodiments of the present disclosure is shown.

[0028] Figure 3 A perspective view showing an example of a side cover according to some embodiments of the present disclosure is shown.

[0029] Figure 4 Shown is shown viewed from the other side Figure 3 A perspective view of an example of a side cover.

[0030] Figure 5 A perspective view showing an example of a side panel according to some embodiments of the present disclosure is shown.

[0031] Figure 6A perspective view showing an example of an insulation molding according to some embodiments of the present disclosure is shown.

[0032] Figure 7 A plan view showing an example of an insulation molding according to some embodiments of the present disclosure is shown.

[0033] Figure 8 The diagram shows a cutting along the cutting line A-A'. Figure 3 A cross-sectional view of an example of a side cover.

[0034] Fig. 9 A perspective view showing an example of a side cover according to some embodiments of the present disclosure is shown.

[0035] Fig.10 Shown is shown viewed from the other side Fig. 9 A perspective view of an example of a side cover.

[0036] Fig.11 A plan view showing an example of an insulation molding according to some embodiments of the present disclosure is shown.

[0037] Fig.12 The cut along the cutting line BB' is shown. Fig. 9 A cross-sectional view of an example of a side cover.

[0038] Fig.13 A flow chart illustrating an example of a method of manufacturing a side cover of a battery module according to some embodiments of the present disclosure is shown. DETAILED DESCRIPTION

[0039] Hereinafter, aspects of some embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The terms or words used in this specification and claims should not be interpreted as limited to the ordinary meaning or dictionary meaning, but should be interpreted as meanings and concepts consistent with the technical idea of ​​the present disclosure based on the principle that the inventor can act as his or her own lexicon compiler to appropriately define the concept of the term in order to explain his or her invention in the best way.

[0040] The embodiments described in this specification and the configurations shown in the accompanying drawings are only some embodiments of the present disclosure, and do not represent all technical ideas, aspects and features of the present disclosure. Therefore, it should be understood that when submitting this application, there may be various equivalents and modifications that can replace or modify the embodiments described herein.

[0041] It will be understood that when an element or layer is referred to as being "on," "connected to," or "bound to" another element or layer, the element or layer may be directly on, directly connected to, or directly bound to the other element or layer, or one or more intervening elements or layers may also be present. When an element or layer is referred to as being "directly on," "directly connected to," or "directly bound to" another element or layer, there are no intervening elements or layers. For example, when a first element is described as being "bound to" or "connected to" a second element, the first element may be directly bound to or directly connected to the second element, or the first element may be indirectly bound to or indirectly connected to the second element via one or more intervening elements.

[0042] In the figure, for the sake of clear explanation, the sizes of various elements, layers, etc. may be exaggerated. The same reference numerals represent the same elements. As used herein, the term "and / or" includes any combination and all combinations of one or more of the relevant listed items. In addition, when describing the embodiments of the present disclosure, the use of "may (may)" relates to "one or more embodiments of the present disclosure". The expressions such as "at least one (kind / person) in ... " and "any one (kind / person) in ... " modify the entire column of elements after a column of elements without modifying the individual elements in the column. When phrases such as "at least one (kind / person) in A, B and C", "at least one (kind / person) in A, B or C", "at least one (kind / person) selected from the group of A, B and C" or "at least one (kind / person) selected from A, B and C" are used to represent a column of elements A, B and C, the phrase can refer to any suitable combination (or subset) and all suitable combinations (or subsets) of A, B and C, such as A, B, C, A and B, A and C, B and C, or A and B and C. As used herein, the term "use" and variations thereof may be considered synonymous with the term "utilize" and variations thereof, respectively. As used herein, the terms "substantially," "approximately," and similar terms are used as terms of approximation rather than as terms of degree, and are intended to account for the inherent variations in measurements or calculations that one of ordinary skill in the art would recognize.

[0043] It will be understood that, although the terms first, second, third, etc. can be used to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms are used to distinguish an element, component, region, layer or part from another element, component, region, layer or part. Therefore, without departing from the teaching of the exemplary embodiment, the first element, first component, first region, first layer or first part discussed below can be referred to as the second element, second component, second region, second layer or second part.

[0044] For ease of description, spatially relative terms such as "under", "below", "below", "above", "on", etc. may be used herein to describe the relationship of one element or feature to another element or features as shown in the figure. It will be understood that, in addition to the orientation depicted in the figure, the spatially relative terms are intended to cover different orientations of the device in use or operation. For example, if the device in the figure is turned over, the elements described as "under" or "below" other elements or features will then be oriented to be "above" the other elements or features. Therefore, the term "under" can cover both above and below. The device can be oriented otherwise (e.g., rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein should be interpreted accordingly.

[0045] The terms used herein are for the purpose of describing the embodiments of the present disclosure and are not intended to limit the present disclosure. As used herein, unless the context clearly indicates otherwise, the singular forms "one" and "a (kind / person)" are also intended to include plural forms. It will also be understood that when the terms "include", "comprise" and / or variations thereof are used in this specification, the stated features, integers, steps, operations, elements and / or components are indicated, but the presence or addition of one or more other features, integers, steps, operations, elements, components and / or their groups are not excluded.

[0046] In addition, any numerical range disclosed and / or described herein is intended to include all sub-ranges of the same numerical precision contained in the described range. For example, the range of "1.0 to 10.0" is intended to include all sub-ranges between the described minimum value 1.0 and the described maximum value 10.0 (and including the described minimum value 1.0 and the described maximum value 10.0), that is, having a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as 2.4 to 7.6 as an example. Any maximum numerical limit described herein is intended to include all lower numerical limits contained therein, and any minimum numerical limit described in this specification is intended to include all higher numerical limits contained therein. Therefore, the applicant reserves the right to modify this specification and the claims to clearly describe any sub-range contained in the scope clearly described herein. All such ranges are intended to be inherently described in this specification so that modifications to clearly describing any such sub-ranges will meet the requirements.

[0047] Referring to two compared elements, features, etc. as "the same" may mean that they are "substantially the same." Thus, the phrase "substantially the same" may include situations with what is considered in the art to be low deviations (e.g., 5% or less deviation). Additionally, when a parameter is referred to as being uniform in a given area, this may mean that it is uniform in terms of average value.

[0048] Throughout the specification, unless otherwise specified, each element may be in the singular or in the plural.

[0049] When any element is referred to as being disposed (or located or positioned) “on (or below)” or “on (or below)” a component, this may mean that the arbitrary element is placed in contact with the upper (or lower) surface of the component, and may also mean that another component may be placed between the component and any element disposed (or located or positioned) on (or below) the component.

[0050] In addition, it will be understood that when an element is referred to as being "coupled," "linked," or "connected" to another element, the elements may be directly "coupled," "linked," or "connected" to each other, or there may be an intervening element between them, through which the element may be "coupled," "linked," or "connected" to another element. In addition, when a component is referred to as being "electrically coupled" to another component, the component may be directly connected to the other component, or there may be an intervening component between them, so that the component and the other component are indirectly connected to each other.

[0051] Throughout the specification, unless otherwise stated, when "A and / or B" is stated, it means A, B, or A and B. That is, "and / or" includes any combination or all combinations of the listed multiple items. Unless otherwise stated, when "C to D" is stated, it means C or greater and D or less.

[0052] A battery pack according to one or more embodiments includes at least one battery module and a pack case having an accommodation space to accommodate the at least one battery module.

[0053] The battery module may include a plurality of battery cells and a module housing. The battery cells may be housed in a stacked form (or stacked arrangement or configuration) inside the module housing. Each battery cell may have a positive electrode terminal and a negative electrode terminal, and may be cylindrical, prismatic, or pouch-shaped depending on the shape of the battery. In this specification, a battery cell may also be referred to as a secondary battery, a battery, or a cell.

[0054] In a battery pack, a single cell stack may constitute a stacked module instead of a battery module. The single cell stack may be accommodated in an accommodation space of a pack case, or may be accommodated in an accommodation space partitioned by a frame, a partition wall, or the like.

[0055] The battery cells may generate a large amount of heat during charging / discharging. The generated heat may accumulate in the battery cells, thereby accelerating the degradation of the battery cells. Therefore, the battery pack may further include a cooling member to remove the generated heat, thereby suppressing the degradation of the battery cells. The cooling member may be provided at the bottom of the accommodation space where the battery cells are provided, but is not limited thereto, and may be provided at the top or side according to the battery pack.

[0056] The battery cell may be configured so that exhaust gas generated inside the battery cell under abnormal operating conditions (also known as thermal runaway or thermal events) is discharged to the outside of the battery cell. The battery pack or battery module may include an exhaust port for exhausting the exhaust gas to prevent or reduce damage to the battery pack or battery module caused by the exhaust gas.

[0057] The battery pack may include a battery and a battery management system (BMS) for managing the battery. The battery management system may include a detection device, a balancing device, and a control device. The battery module may include a plurality of battery cells connected in series and / or in parallel with each other. The battery modules may be connected in series and / or in parallel with each other.

[0058] The detection device may detect the state of the battery (e.g., voltage, current, temperature, etc.) to output state information indicating the state of the battery. The detection device may detect the voltage of each cell or each battery module constituting the battery. The detection device may detect the current flowing through the battery module or each battery module constituting the battery pack. The detection device may also detect the temperature of the cell and / or module at at least one point of the battery and / or the ambient temperature.

[0059] The balancing device can perform balancing operations on the battery module and / or the monomers constituting the battery module. The control device can receive status information (e.g., voltage, current, temperature, etc.) of the battery module from the detection device. The control device can monitor and calculate the status of the battery module (e.g., voltage, current, temperature, state of charge (SOC), life (state of health (SOH)), etc.) based on the status information received from the detection device. In addition, based on the monitored status information, the control device can perform control functions (e.g., temperature control, balancing control, charge / discharge control, etc.) and protection functions (e.g., over-discharge, over-charge, over-current protection, short circuit, fire extinguishing function, etc.). In addition, the control device can perform wired or wireless communication functions with external devices of the battery pack (e.g., higher-level controllers or vehicles, chargers, power conversion systems, etc.).

[0060] The control device can control the charging / discharging operation and the protection operation of the battery. To this end, the control device can include a charging / discharging control unit, a balancing control unit and / or a protection unit.

[0061] A battery management system is a system that monitors the battery status and performs diagnostic and control, communication, and protection functions, and can calculate the charge / discharge status, calculate the battery life or state of health (SOH), cut off battery power as needed (e.g., relay control), control thermal management (e.g., cooling, heating, etc.), perform high-voltage interlock functions, and / or can detect and / or calculate insulation and short circuit conditions.

[0062] A relay can be a mechanical contactor that switches on and off by the magnetic force of a coil or a semiconductor switch such as a metal oxide semiconductor field effect transistor (MOSFET).

[0063] The relay control has a function of cutting off the power supply from the battery in the event of a problem in the vehicle and the battery system (or when a problem occurs in the vehicle and the battery system), and may include one or more relays and pre-charge relays at the positive terminal and the negative terminal, respectively.

[0064] In pre-charge control, when the battery load is connected, there is a risk of inrush current occurring in the high-voltage capacitor on the input side of the inverter. Therefore, in order to prevent or reduce inrush current when starting the vehicle, the pre-charge relay may be operated before the main relay is connected, and a pre-charge resistor may be connected.

[0065] The high-voltage interlock is a circuit that uses a small signal to detect whether all high-voltage parts of the entire vehicle system are connected, and may have a function of forcibly disconnecting a relay in the event (or when a disconnection occurs) at even one location on the entire loop.

[0066] Figure 1 A perspective view showing an example of a battery cell 10 according to some embodiments of the present disclosure is shown. The battery cell 10 may include: one or more electrode assemblies wound or stacked, with a separator (e.g., an insulating member) disposed between a positive electrode and a negative electrode; a case 110 including the electrode assembly disposed therein; and a cap plate 120 coupled to one open end of the case 110 (and / or at least partially inserted into one open end of the case 110). Figure 1 The battery cell 10 shown in FIG. 1 may be a secondary battery.

[0067] Each of the positive electrode and the negative electrode may include a current collector made of a conductive material such as a thin metal foil, the current collector having a coated portion on which an active material is coated and an uncoated portion on which the active material is not coated.

[0068] The positive electrode and the negative electrode are wound after placing a separator as an insulating member therebetween. However, the embodiment according to the present disclosure is not limited thereto, and the electrode assembly may have a structure in which positive electrodes and negative electrodes each made of a plurality of sheets are alternately stacked with a separator placed therebetween.

[0069] The housing 110 may form the overall appearance of the battery cell 10 and may be made of a conductive metal such as aluminum, an aluminum alloy, or nickel-plated steel. In addition, the housing 110 may provide a space in which an electrode assembly is accommodated. According to some embodiments, the housing 110 may be a prismatic housing, and the battery cell 10 may be a prismatic battery cell. However, the scope of the embodiments according to the present disclosure is not limited thereto, and the battery cell 10 may be a battery cell of any shape such as a prismatic battery cell, a cylindrical battery cell, or a pouch-shaped battery cell.

[0070] The cap plate 120 may be coupled to the open end of the housing 110 to seal the housing 110. The housing 110 and the cap plate 120 may include a conductive material. According to some embodiments, the upper end of the housing 110 may be open, and the cap plate 120 may seal the open upper end of the housing 110.

[0071] A positive electrode terminal 130_1 electrically connected to the positive electrode and a negative electrode terminal 130_2 electrically connected to the negative electrode may be coupled to the cap plate 120. For example, the positive electrode terminal 130_1 and the negative electrode terminal 130_2 may be disposed to protrude outward through the cap plate 120.

[0072] According to some embodiments, the vent 140 may be provided in at least one surface of the battery cell 10 (e.g., in the illustrated example, the upper surface of the battery cell 10, i.e., the cap plate 120). The vent 140 may be configured to open when an internal pressure equal to or higher than a threshold pressure (e.g., a set or predetermined threshold pressure) is detected in the battery cell 10.

[0073] According to some embodiments, the cap plate 120 may include an electrolyte inlet 150. For example, the electrolyte inlet 150 may be a through hole provided in the cap plate 120. The electrolyte inlet 150 may be formed to allow the electrolyte to be injected into the housing 110 therethrough after the cap plate 120 is coupled to the opening of the housing 110 to seal the housing 110. The electrolyte inlet 150 may be sealed with a sealing member after the electrolyte is injected.

[0074] The battery cell 10 may be a lithium (Li) battery cell, a sodium (Na) battery cell, or the like. However, the scope of the embodiments according to the present disclosure is not limited thereto, and the battery cell 10 includes any battery that can repeatedly provide power due to charging and discharging. According to some embodiments, in the case where the battery cell 10 is a Li battery cell, the battery cell 10 may be used in an electric vehicle (EV) due to excellent life characteristics and high rate characteristics. In addition, the battery cell 10 may be used in hybrid vehicles such as plug-in hybrid electric vehicles (PHEVs). Li battery cells may be used in fields that require a large amount of power storage. For example, Li battery cells may be used in electric bicycles, electric tools, and the like.

[0075] Figure 2 An exploded perspective view showing an example of exploded parts of a battery module 1 according to an embodiment of the present disclosure is shown. Figure 2 According to some embodiments of the present disclosure, a battery module 1 may include a cell stack, a frame 20, 32, 34, 40 accommodating the cell stack therein, and a bus bar holder assembly 50. According to some embodiments, the battery module 1 may be referred to as a battery pack. According to some embodiments, the battery module 1 may be included in a vehicle.

[0076] The battery module 1 may include a cell stack. The cell stack may include a plurality of battery cells 10 stacked in one direction. According to some embodiments, in the cell stack, the battery cells 10 may be arranged in one direction such that wider surfaces of the battery cells 10 face each other.

[0077] According to some embodiments, each of the battery cells 10 may include a housing, an electrode assembly contained inside the housing together with an electrolyte, and a cover plate that seals the housing. Each of the electrode assemblies may be formed by sequentially winding or stacking a negative electrode plate, a separator, and a positive electrode plate. A negative electrode plate implemented as a metal foil such as copper (Cu), a Cu alloy, nickel (Ni), or a Ni alloy may be applied or coated with a negative electrode active material such as graphite or carbon (C). A positive electrode plate implemented as a metal foil such as aluminum (Al) or an Al alloy may be applied or coated with an active material such as a transition metal oxide. Each of the negative electrode plate and the positive electrode plate may be provided with an uncoated portion, that is, an area where an active material is not applied. A negative electrode tab may be connected to the uncoated portion of the negative electrode, and a positive electrode tab may be connected to the uncoated portion of the positive electrode. The negative electrode tab and the positive electrode tab connected in this manner may be electrically connected to a negative electrode terminal and a positive electrode terminal provided on the cover plate, respectively. The negative electrode terminal and the positive electrode terminal provided on the cover plate may be electrically connected to a bus bar. However, the structure of the battery cell 10 is not limited thereto and may be appropriately changed as needed. Figure 2The structure shown in , and can be appropriately changed as needed.

[0078] The cell stack may be accommodated in the frame 20, 32, 34, 40. In some embodiments, the frame 20, 32, 34, 40 may include: a pair of side covers 20, disposed on opposite sides of the cell stack; a pair of end plates 32, vertically coupled to the side covers 20 and supporting the outermost surface of the cell stack in one direction (i.e., the direction of arrangement of the battery cells 10); an end insulating cover 34, disposed between the cell stack and the end plates 32; and an upper cover 40, disposed above the cell stack (or above the bus bar holder assembly 50 above the cell stack). According to some embodiments, a lower plate or lower cover may be disposed below the cell stack to support the cell stack from below. The cell stack, the bus bar holder assembly 50, etc. may be accommodated in the frame 20, 32, 34, 40.

[0079] In some embodiments, each of the side covers 20 may include a plate-shaped side plate having a plurality of coupling holes and an insulating molding provided with a coupling portion filling the coupling holes provided in the side plate. Figures 3 to 12 Describe its characteristics in more detail.

[0080] The bus bar holder assembly 50 may include: a plurality of bus bars electrically connected to the battery cells; a bus bar holder supporting the bus bars; and a circuit board electrically connected to the bus bars and having various circuits and components mounted thereon. The bus bar holder may be disposed above the cover plate and support the bus bars. For example, the bus bar holder may be a generally rectangular plate and may be made of an insulating material.

[0081] The bus bar holder may be provided with a plurality of through holes through which the positive electrode terminal and the negative electrode terminal of the cap plate are exposed. The positive electrode terminal and the negative electrode terminal may be exposed through the through holes formed in the bus bar holder, and the bus bar may be electrically connected to the exposed positive electrode terminal and the negative electrode terminal.

[0082] The busbar can electrically connect the positive electrode terminal and the negative electrode terminal. The busbar can connect the battery cells 10 in series and / or in parallel. To this end, the busbar can be provided as a plurality of busbars. In some embodiments, the busbar can electrically connect the positive electrode terminal of one battery cell 10 to the positive electrode terminal or the negative electrode terminal of another battery cell 10. In addition or in another example, the busbar can electrically connect the negative electrode terminal of one battery cell 10 to the positive electrode terminal or the negative electrode terminal of another battery cell 10. The busbar can be connected to the positive electrode terminal and / or the negative electrode terminal by welding or the like. Each area of ​​the battery cell 10 other than the positive electrode terminal and the negative electrode terminal can be insulated from the busbar by a busbar holder. The circuit board can be provided between the busbar and the top plate, and the busbar can be electrically connected to the circuit board.

[0083] Various components for measuring state information of the battery cell 10 (such as the voltage and / or temperature of the battery cell 10), various components or circuits configured to control and / or manage the battery cell 10, etc. may be mounted on the circuit board. According to some embodiments, the circuit board may include a battery management system (BMS). According to some embodiments, the circuit board may be electrically connected to the outside of the battery module 1 through a separate connector.

[0084] Figure 3 A perspective view showing an example of a side cover 20 according to an embodiment of the present disclosure is shown, and Figure 4 Shown is shown viewed from the other side Figure 3 20 is a perspective view of an example of a side cover 20. Figure 3 The perspective view of FIG. 1 may mainly show a first surface (eg, a surface facing the cell stack) of the side cover 20 according to an embodiment of the present disclosure, and Figure 4 The perspective view of FIG. 1 may mainly show the second surface of the side cover 20 according to an embodiment of the present disclosure, that is, a surface opposite to the first surface.

[0085] Reference Figure 3 and Figure 4 The side cover 20 may include a side plate 210 and an insulating molded part 220. The side plate 210 may have a plate shape elongated in one direction (eg, the direction of arrangement of the battery cells) and may be provided with a plurality of coupling holes. Figure 5 The specific configuration of the side plate 210 is described in more detail.

[0086] In some embodiments, the insulating molding 220 may have a plate-shaped body that is elongated in one direction, wherein the plate-shaped body may cover at least a portion of the first surface (e.g., the surface facing the unit stack) of the side cover 20. In addition, the insulating molding 220 may be provided with a coupling portion that fills the coupling hole of the side plate 210. For example, the coupling portion of the insulating molding 220 may include a plurality of coupling protrusions that are integrally provided with the plate-shaped body of the insulating molding 220. Figure 6 and Figure 7 A specific configuration of the insulation molding 220 according to the embodiment is described in more detail.

[0087] In the battery module, one side cover 20 may be disposed to face one side surface of the cell stack, and a pair of side covers 20 may be disposed on opposite sides of the cell stack. The insulation molding 220 may perform a function of insulating the side plate 210 and the cell stack.

[0088] Figure 5 2 is a perspective view showing an example of a side plate 210 according to an embodiment of the present disclosure. Figure 5, the side plate 210 may have a plate shape that is elongated in one direction (i.e., the direction of arrangement of the battery cells in the battery module). According to some embodiments, the side plate 210 may be provided with a recess 212. For example, in the side plate 210, at least a portion of a first surface (e.g., a surface facing a cell stack in the battery module) may be recessed toward a second surface opposite to the first surface, thereby forming the recess 212. According to some embodiments, the recess 212 of the side plate 210 may be covered with at least a portion of the insulating molding (e.g., a main body of the insulating molding or a first plate of the insulating molding).

[0089] According to some embodiments, the side plate 210 may be provided with a plurality of coupling holes 214. According to some embodiments, the coupling holes 214 may be provided in the recess 212 of the side plate 210. The coupling portion of the insulation molding may fill the coupling holes 214 provided in the side plate 210. Figure 5 In the embodiment, the side plate 210 is shown as having 80 circular coupling holes. The number, shape, arrangement, etc. of the coupling holes 214 are not limited to Figure 5 The number, shape, arrangement, etc. shown in FIG. 1 and can be appropriately selected as needed.

[0090] According to some embodiments, the side plate 210 may include at least a portion of a metal material suitable for maintaining the strength of the battery module and suitable for connection to another plate or another cover by welding.

[0091] According to some embodiments, the opposite ends of the side plate 210 may be fastened or connected to the end plate. For example, the opposite ends of the side plate 210 may have a partially protruding structure, respectively, and may be fastened or connected to the end plate by at least a portion of the protruding portion. In addition, at least a portion of the side plate 210 that contacts the end plate may be fixed by, for example, welding.

[0092] Figure 6 A perspective view showing an example of an insulation molding 220 according to an embodiment of the present disclosure is shown, and Figure 7 A plan view showing an example of an insulation molding 220 according to an embodiment of the present disclosure is shown. Figure 7 The plan view of FIG. 2 may show an example in which the insulation molding 220 according to an embodiment of the present disclosure is viewed from above (eg, from the upper cover side of the battery module or in a plan view). Figure 6 and Figure 7 The insulating molded part 220 may have a plate-shaped body 222 that is elongated in one direction (e.g., the direction of arrangement of the battery cells in the battery module, i.e., the length direction of the side plate). In some embodiments, the plate-shaped body 222 of the insulating molded part 220 may cover at least a portion of the first surface of the side plate. For example, the body 222 of the insulating molded part 220 may fill at least a portion of the recess of the side plate.

[0093] According to some embodiments, the insulating molding 220 may be provided with a coupling portion that fills the coupling hole of the side plate. For example, the coupling portion of the insulating molding 220 may include a plurality of coupling protrusions 224 that are integrally provided with the plate-shaped body 222 of the insulating molding 220. In a specific example, the insulating molding 220 with the first surface (i.e., Figure 7 The second surface (i.e., the upper surface in the battery module or the surface facing the single-cell stack in the battery module) is opposite to the upper surface in the battery module or the surface facing the single-cell stack in the battery module Figure 7 at least a portion of the lower surface in the Figure 7 The insulating molding 220 protrudes downwardly from the side plate to form a coupling protrusion 224. The coupling protrusions 224 of the insulating molding 220 may be provided in the same number as the coupling holes of the side plate, and may be arranged in the same manner as the coupling holes of the side plate. The non-protruding portion of the second surface of the insulating molding 220 may cover at least a portion of the first surface of the side plate, and the coupling protrusions 224 of the insulating molding 220 may fill the coupling holes of the side plate, respectively. Therefore, the side plate and the insulating molding 220 may be firmly coupled.

[0094] Figure 8 The diagram shows a cutting along the cutting line A-A'. Figure 3 2 is a cross-sectional view of an example of the side cover 20. According to some embodiments, the insulation molding 220 may be manufactured by an injection molding process to be integrally formed with the side plate 210.

[0095] For example, first, the plate-shaped side plate 210 including the coupling hole may be placed in the injection mold. For example, the side plate 210 may be placed in the lower mold of the injection mold, and then the injection mold may be assembled by fitting the upper mold to the lower mold.

[0096] Thereafter, the molten resin may be injected into the cavity inside the injection mold in which the side plate 210 is placed. In a specific example, a recessed portion in which at least a portion of a first surface (i.e., a surface facing a cell stack in a battery module) is recessed toward a second surface opposite to the first surface may be formed in the side plate 210. Thus, a cavity corresponding to the recessed portion may be formed between the injection mold and the first surface of the side plate 210. The molten resin may be injected into the cavity. In addition, a portion of the molten resin injected into the cavity may fill the coupling hole of the side plate 210.

[0097] Thereafter, in response to the molten resin being cooled, the insulation molding 220 having the coupling portion filling the coupling hole may be molded. For example, the portion of the injected molten resin filling the cavity between the injection mold and the first surface of the side plate 210 may be cooled to form a plate-shaped body of the insulation molding 220. In addition, the portion of the molten resin filling the coupling hole of the side plate 210 may be cooled to form a coupling protrusion of the insulation molding 220.

[0098] Thereafter, the integrated side cover 20 including the side plate 210 and the insulation molding 220 can be removed from the inside of the injection mold. Since the side cover 20 is manufactured by the insert injection method, the integrated side cover 20 can be taken out while the insulation molding 220 covers at least a portion of the side plate 210 and the coupling protrusion of the insulation molding 220 fills the coupling hole of the side plate 210 (i.e., the side plate 210 and the insulation molding 220 are coupled).

[0099] Unlike the case of the end plate provided at the opposite end of the cell stack in the direction of arrangement of the battery cells, since the side cover 20 is provided on the opposite side of the cell stack, the supporting pressure of the cell stack is not high. Therefore, the insulating molding 220 can be manufactured by a thin film injection method so that the insulating molding 220 thinly covers the surface of the side plate 210. The thickness of the insulating molding 220 can be freely selected as long as short shot does not occur.

[0100] According to some embodiments, the insulation molding 220 may include a material having one or more of insulating, flame-retardant, non-combustible, or fire-resistant properties.

[0101] Due to the side cover 20 according to the present disclosure, compared with the case where the insulating paper is attached to the side plate 210 using an adhesive, the strength of the battery module may be increased and an excellent insulating effect may be expected.

[0102] In addition, compared with the case where the insulating paper is attached by heat fusion, in response to the insulation molding 220 according to the present disclosure being injection-molded at a low temperature, heat damage applied to the side plate 210 including a metal material can be reduced, and thus the defect rate due to warping of the side plate can be reduced. In addition, the reduced cooling time can reduce the production cycle time, which can improve productivity.

[0103] Fig. 9 A perspective view showing an example of a side cover 60 according to an embodiment of the present disclosure is shown, and Fig.10 Shown is shown viewed from the other side Fig. 9 1 is a perspective view of an example of a side cover 60 . Fig. 9 The perspective view of FIG. 1 may mainly show the first surface of the side cover 60 (eg, the surface facing the cell stack), and Fig.10 The perspective view of FIG. 6 may mainly show a second surface of the side cover 60 according to an embodiment of the present disclosure, the second surface being opposite to the first surface.

[0104] Reference Fig. 9 and Fig.10, the side cover 60 may include a side plate 610 and an insulating molded part 620. The side plate 610 may have a plate shape elongated in one direction (eg, the direction of arrangement of the battery cells) and may be provided with a plurality of coupling holes. Fig. 9 and Fig.10 The side plate 610 in the side cover 60 described above can be the same as that in the Figure 5 The side panels 210 described above are the same or similar. Figure 5 Most of the features of the side panel 210 described can be applied in the same or similar manner to other devices including Fig. 9 and Fig.10 The side plate 610 in the side cover 60 .

[0105] According to some embodiments, the insulating molding 620 may include: a first plate covering at least a portion of a first surface of the side plate 610 facing the unit stack; and a second plate covering at least a portion of a second surface of the side plate 610 opposite to the first surface. In addition, the insulating molding 620 may be provided with a coupling portion filling the coupling hole of the side plate 610. For example, the coupling portion of the insulating molding 620 may include a plurality of coupling columns integrally provided with the first plate and the second plate of the insulating molding 620. This will be described later. Fig.11 The specific configuration of the insulation molding 620 according to these embodiments is described in more detail.

[0106] In the battery module, a single side cover 60 may be provided to face one side surface of the cell stack, or a pair of side covers 60 may be provided on opposite sides of the cell stack. Fig. 9 and Fig.10 The side cover 60 may be provided to replace Figure 2 The side cover 60 having the insulating molding 620 covering the opposite sides of the side plate 610 may be used to not only insulate the side plate 610 and the cell stack but also prevent or reduce heat transfer to adjacent modules.

[0107] Fig.11 A plan view showing an example of an insulation molding 620 according to an embodiment of the present disclosure is shown. Fig.11 The plan view of FIG. 1 may show an example in which the insulation molding 620 according to an embodiment of the present disclosure is viewed from above (eg, the upper cover side of the battery module, or in a plan view). Fig.11, the insulating molded part 620 may include a first plate 622 and a second plate 624, both of which are elongated in one direction (e.g., the direction of arrangement of the battery cells in the battery module, i.e., the length direction of the side plate). The first plate 622 and the second plate 624 of the insulating molded part 620 may have the same or similar shapes. In some embodiments, the first plate 622 of the insulating molded part 620 may cover at least a portion of the first surface of the side plate (e.g., the surface facing the cell stack in the battery module), and the second plate 624 of the insulating molded part 620 may cover at least a portion of the second surface of the side plate opposite to the first surface. For example, the side plate may be provided with a first recess formed in at least a portion of the first surface and recessed toward the second surface opposite to the first surface, and the first plate 622 of the insulating molded part 620 may fill at least a portion of the first recess of the side plate. Additionally or in another example, the side plate may be provided with a second recess formed in at least a portion of the second surface and recessed toward the first surface, and the second plate 624 of the insulating molded part 620 may fill at least a portion of the second recess of the side plate. In another example, the side panels may have a flat configuration without recesses.

[0108] According to some embodiments, the insulating molding 620 may be provided with a coupling portion that fills the coupling hole of the side plate. For example, the coupling portion of the insulating molding 620 may include a plurality of coupling columns 626 that are integrally provided with the first plate 622 and the second plate 624 of the insulating molding 620. In a specific example, the insulating molding 620 may be provided with a plurality of coupling columns 626 that connect the first plate 622 and the second plate 624. The coupling columns 626 of the insulating molding 620 may be provided in the same number as the number of coupling holes of the side plate. The coupling columns 626 of the insulating molding 620 may fill the coupling holes of the side plate, respectively. Therefore, the side plate and the insulating molding 620 may be firmly combined.

[0109] Fig.12 The cutting along the cutting line BB' is shown. Fig. 9 60 is a cross-sectional view of an example of a side cover 60. According to some embodiments, the insulation molding may be manufactured by an injection molding method to be integrally formed with the side plate 610.

[0110] For example, first, the plate-shaped side plate 610 including the combination hole may be placed in the injection mold. For example, the side plate 610 may be placed in the lower mold of the injection mold, and then the injection mold may be assembled by assembling the upper mold to the lower mold.

[0111] Thereafter, the molten resin may be injected into the cavity inside the injection mold in which the side plate 610 is placed. In a specific example, a recess in which at least a portion of a first surface (i.e., a surface facing the cell stack in the battery module) is recessed toward a second surface opposite to the first surface may be formed in the side plate 610. Thus, a cavity corresponding to the recess may be formed between the injection mold and the first surface of the side plate 610. A cavity may also be formed between the second surface of the side plate 610 and the injection mold. The molten resin may be injected into the cavity. In addition, a portion of the molten resin injected into the cavity may fill the coupling hole of the side plate 610.

[0112] Thereafter, in response to the molten resin being cooled, an insulating molded part having a bonding portion filling the bonding hole may be molded. For example, a portion of the injected molten resin filling the cavity between the injection mold and the first surface of the side plate 610 may be cooled to form a first plate 622 of the insulating molded part. Another portion of the injected molten resin filling the cavity between the injection mold and the second surface of the side plate 610 may be cooled to form a second plate 624 of the insulating molded part. In addition, a portion of the molten resin filling the bonding hole of the side plate 610 may be cooled to form a bonding protrusion connecting the first plate 622 and the second plate 624 of the insulating molded part.

[0113] Thereafter, the integrated side cover 60 including the side plate 610 and the insulation molding can be removed from the inside of the injection mold. Since the side cover 60 is manufactured by the insert injection method, the integrated side cover 60 can be taken out with the first plate 622 of the insulation molding covering at least a portion of the first surface of the side plate 610, the second plate 624 of the insulation molding covering at least a portion of the second surface of the side plate 610, and the coupling protrusion of the insulation molding filling the coupling hole of the side plate 610 (i.e., the side plate 610 and the insulation molding being coupled).

[0114] Unlike the case of the end plate provided at the opposite end of the cell stack in the direction of arrangement of the battery cells, since the side cover 60 is provided on the opposite side of the cell stack, the supporting pressure of the cell stack is not high. Therefore, the insulating molded part can be manufactured by a thin film injection method so that the insulating molded part thinly covers the surface of the side plate 610. The thickness of the insulating molded part 220 can be freely selected as long as insufficient molding does not occur.

[0115] According to some embodiments, the insulating molding may include a material having one or more of insulating, flame retardant, non-combustible or fireproof properties. According to the above-mentioned embodiment in which the insulating molding is manufactured to cover the opposite surface of the side plate 610, the integrated side cover 60 can perform not only an insulating function but also a function of preventing or reducing heat transfer to adjacent modules.

[0116] Fig.13 A flowchart showing an example of a method 1300 for manufacturing a side cover of a battery module according to an embodiment of the present disclosure is shown. According to some embodiments, the method 1300 for manufacturing a side cover may be performed by, for example, a side cover manufacturing device or a battery module manufacturing device (hereinafter, referred to as a manufacturing device). The side cover may include a plate-shaped side plate provided with a plurality of coupling holes and an insulating molded part provided with a coupling portion filling the coupling holes provided in the side plate. In some embodiments, the insulating molded part may be formed integrally with the side plate by insert injection.

[0117] For example, first, in S1310, the manufacturing equipment (e.g., the placement unit of the manufacturing equipment) may place a plate-shaped side panel including a plurality of coupling holes in the injection mold. For example, the manufacturing equipment may place the side panel in a lower mold of the injection mold, and then assemble the injection mold by fitting the upper mold to the lower mold.

[0118] Thereafter, in S1320 , the manufacturing apparatus (eg, a placement unit of the manufacturing apparatus) may inject molten resin into the cavity inside the injection mold in which the side panel is placed.

[0119] According to some embodiments, a first recessed portion in which at least a portion of a first surface (i.e., a surface facing a cell stack in a battery module) is recessed toward a second surface opposite to the first surface may be formed in the side plate. Thus, a cavity corresponding to the first recessed portion may be formed between the injection mold and the first surface of the side plate. Molten resin may be injected into the cavity, and a portion of the molten resin injected into the cavity may fill the coupling hole of the side plate.

[0120] According to some embodiments, in addition to between the injection mold and the first surface of the side panel, a cavity may also be formed between the second surface of the side panel and the injection mold. For example, a second recess in which at least a portion of the second surface is recessed toward the first surface may be formed in the side panel, and thus a cavity corresponding to the second recess may be formed between the injection mold and the second surface of the side panel. Additionally or in another example, a second recess may be formed in a surface of the injection mold facing the second surface of the side panel, and thus a cavity corresponding to the second recess may be formed between the injection mold and the second surface of the side panel. Molten resin may be injected into the cavity, and a portion of the molten resin injected into the cavity may fill the coupling hole of the side panel.

[0121] Thereafter, in S1330 , the manufacturing apparatus (eg, a placement unit of the manufacturing apparatus) may cool the molten resin to form an insulation molding provided with a coupling portion filling the coupling hole.

[0122] In some embodiments, the portion of the injected molten resin that fills the cavity between the injection mold and the first surface of the side plate can be cooled to form a plate-shaped body of the insulation molding. In addition, the portion of the molten resin that fills the coupling hole of the side plate can be cooled to form a coupling protrusion of the insulation molding.

[0123] According to some embodiments, a portion of the injected molten resin that fills the cavity between the injection mold and the first surface of the side plate may be cooled to form a first plate of the insulation molding. Another portion of the injected molten resin that fills the cavity between the injection mold and the second surface of the side plate may be cooled to form a second plate of the insulation molding. In addition, a portion of the molten resin that fills the coupling hole of the side plate may be cooled to form a coupling protrusion of the insulation molding that connects the first plate and the second plate.

[0124] Thereafter, in S1340 , the manufacturing apparatus (eg, a removing unit of the manufacturing apparatus) may remove the integrated side cover including the side plate and the insulation molding from the inside of the injection mold.

[0125] Fig.13 The flowchart and the above description are examples of the present disclosure, and the scope of the embodiments according to the present disclosure is not limited to Fig.13 For example, one or more operations in the flowcharts and the above description may be added / modified / deleted, the order of one or more operations may be changed, and one or more operations may be performed simultaneously.

[0126] Although some aspects of the present invention have been described with reference to some embodiments and the accompanying drawings showing aspects of the embodiments, the embodiments according to the present invention are not limited thereto. Those skilled in the art to which the present invention belongs may make various modifications and changes within the scope of the technical spirit of the present invention and the appended claims and their equivalents.

Claims

1. A battery module, comprising: a cell stack including a plurality of battery cells stacked in one direction; as well as a side cover, on an opposite side of the monolithic stack, Wherein, each of the side covers comprises: A plate-shaped side panel including a plurality of coupling holes; and The insulating molding includes a coupling portion filling the plurality of coupling holes.

2. The battery module according to claim 1, wherein: The insulating molded part is integrally provided with the side plate by insert injection.

3. The battery module according to claim 1, wherein: The insulation molding includes a plate-shaped body covering at least a portion of a first surface of the side plate facing the unit stack, and the coupling portion includes a plurality of coupling protrusions provided integrally with the plate-shaped body.

4. The battery module according to claim 3, wherein: The side plate includes a recessed portion provided in at least a portion of the first surface and recessed toward a second surface opposite to the first surface, and The plate-shaped main body of the insulation molding covers the recessed portion of the side plate.

5. The battery module according to claim 1, wherein: The insulation molding includes a plate-shaped first plate covering at least a portion of a first surface of the side plate facing the unit stack and a plate-shaped second plate covering at least a portion of a second surface of the side plate opposite to the first surface.

6. The battery module according to claim 5, wherein: The coupling portion is integrally provided with the first plate and the second plate, and includes a plurality of coupling columns coupling the first plate and the second plate.

7. The battery module according to claim 5, wherein: The side plate includes a recessed portion in at least a portion of the first surface and recessed toward the second surface, and The first plate of the insulation molding covers the recessed portion of the side plate.

8. The battery module according to claim 1, wherein: Each of the battery cells includes a prismatic battery cell.

9. The battery module according to claim 1, further comprising: a pair of end plates supporting the outermost surfaces of the single body stack in the one direction; as well as The end insulating cover is disposed between the single body stack and the end plate.

10. A side cover of a battery module, the side cover comprising: A plate-shaped side panel including a plurality of coupling holes; as well as The insulating molding includes a coupling portion filling the plurality of coupling holes.

11. The side cover according to claim 10, wherein: The insulating molded part is integrally provided with the side plate by insert injection.

12. The side cover according to claim 10, wherein: The insulation molding includes a plate-shaped body covering at least a portion of a first surface of the side plate, and the coupling portion includes a plurality of coupling protrusions provided integrally with the plate-shaped body.

13. The side cover according to claim 10, wherein: The insulation molding includes a plate-shaped first plate covering at least a portion of a first surface of the side plate and a plate-shaped second plate covering at least a portion of a second surface of the side plate opposite to the first surface.

14. The side cover according to claim 13, wherein: The coupling portion is integrally provided with the first plate and the second plate, and includes a plurality of coupling columns coupling the first plate and the second plate.

15. A method for manufacturing a side cover of a battery module, the method comprising the following steps: placing a plate-shaped side panel including a plurality of coupling holes in an injection mold; injecting molten resin into the cavity inside the injection mold where the side plate is placed; cooling the molten resin to form an insulation molding including a bonding portion filling the plurality of bonding holes; and The integrated side cover including the side plate and the insulation molding is removed from the inside of the injection mold.

16. The method according to claim 15, wherein: The insulation molding includes a plate-shaped body covering at least a portion of the side plate, and the coupling portion includes a plurality of coupling protrusions provided integrally with the plate-shaped body.

17. The method according to claim 15, wherein: The side plate includes a recessed portion provided in at least a portion of the first surface and recessed toward a second surface opposite to the first surface, and The cavity into which the molten resin is injected is the recessed portion of the side plate.

18. The method according to claim 15, wherein: The insulating molding includes a plate-shaped first plate covering at least a portion of a first surface of the side plate and a plate-shaped second plate covering at least a portion of a second surface of the side plate opposite to the first surface, and The coupling portion is integrally provided with the first plate and the second plate, and includes a plurality of coupling columns coupling the first plate and the second plate.

19. The method according to claim 15, wherein: The cavity into which the molten resin is injected is on a first surface of the side plate and a second surface opposite to the first surface.

20. The method according to claim 15, wherein: The step of placing the side panel in the injection mold includes positioning the side panel in a lower mold of the injection mold and fitting an upper mold of the injection mold to the lower mold.

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