Battery module and battery pack with enhanced safety

Abstract

The battery module according to the present invention comprises: a cell assembly having a plurality of mutually stacked battery cells; a module case accommodating the cell assembly in an internal space; and a cover portion coupled to an outer surface of the module housing and having a barrier layer disposed between the module housing and the cover portion to block entry and exit of flames and reduce heat transfer, in which the barrier layer may be foamed into a foam form and coupled to the cover portion to be integrally formed with the cover portion.

Description

Technical Field

[0001] The present disclosure relates to a battery module and a battery pack, and more particularly, to a battery module and a battery pack capable of delaying heat transfer as much as possible by blocking the entry and exit of flames and minimizing heat transfer such as heat conduction and heat radiation when a thermal event occurs. This application is based on and claims priority to Korean Patent Application No. 10-2023-0123386, filed with the Korean Intellectual Property Office on September 15, 2023, the disclosure of which is incorporated herein by reference in its entirety. Background Art

[0002] A secondary battery that converts electrical energy into chemical energy and can be repeatedly charged and discharged is called a secondary battery to distinguish it from a primary battery that cannot be used again after one use.

[0003] Secondary batteries include lithium-ion secondary batteries, nickel-cadmium (Ni-Cd) batteries, lead-acid batteries, nickel-metal hydride (Ni-MH) batteries, air zinc batteries, alkaline manganese batteries, etc. Among these batteries, lead-acid batteries and lithium-ion secondary batteries are the most actively commercialized secondary batteries.

[0004] In particular, lithium-ion secondary batteries have advantages such as high energy storage density, light weight and miniaturization, excellent safety, low discharge rate, and long life, so they have recently been actively used as electric vehicle batteries. For reference, lithium-ion secondary batteries are generally classified into cylindrical, square, and pouch types according to the manufacturing form, and their application ranges from electric vehicle batteries to ESS batteries and other electrical devices.

[0005] Currently, the operating voltage of a single lithium-ion secondary battery is about 2.5V to 4.5V. Therefore, in order to apply secondary batteries as an energy source for electric vehicles, multiple lithium-ion battery cells are connected in series and / or in parallel to form a battery module, and the battery modules are connected in series and / or in parallel to form a battery pack.

[0006] On the other hand, since secondary batteries involve chemical reactions during charging and discharging, the performance of secondary batteries may deteriorate when used in an environment above the appropriate temperature, and there is always a possibility of accidental ignition or explosion when thermal control is not performed at the appropriate temperature. In addition, the battery module has a structure in which these secondary batteries are densely accommodated inside the module case, and thus, if any one of the secondary batteries becomes a triggering cell due to thermal runaway, a chain reaction of igniting the secondary cells may be more easily caused due to the rapid heat and flame propagation to the surrounding secondary cells.

[0007] Accordingly, a cover portion for preventing chain ignition and heat transfer to adjacent battery modules is provided on the outer surface of the battery module, and the cover portion may generally be composed of multiple layers. For example, the cover portion may be provided in a layered structure including a frame cover corresponding to the shape of the outer surface of the battery module and at least one inner surface layer laminated within the frame cover.

[0008] The cover portion is generally made of a refractory material, which can meet the refractory conditions for withstanding heat, but there may be limitations in effectively blocking or delaying flame transfer, heat conduction, or heat radiation generated during a thermal event between modules. Therefore, it is necessary to improve the structure of the cover portion such that the entry and exit of flames can be blocked and heat transfer such as heat conduction and heat radiation can be minimized.

[0009] In addition, an additional adhesive layer is inserted during the lamination process between the frame cover and the inner surface layer, and it is also necessary to improve the durability problem of the cover portion, such as peeling of the inner surface layer due to flames or high heat.

[0010] Furthermore, in the existing manufacturing process of the cover portion, the frame cover and the inner surface layer are provided for each component separately, and separate lamination and stamping processes are required, resulting in problems of increasing the tack time during the module manufacturing process, as well as the manufacturing unit cost and reducing productivity. Summary of the Invention

[0011] Technical Problem

[0012] The present disclosure is designed to solve the problems of the related art, and thus the present disclosure relates to providing a battery module in which when a thermal event occurs, the entry and exit of flames can be blocked and heat transfer such as heat conduction and heat radiation can be minimized, thereby suppressing flame propagation between modules as much as possible and delaying chain heat transfer, and reducing the additional lamination and stamping processes required for each component in the manufacturing process of the existing cover portion for blocking flames, thereby reducing the takt time and manufacturing unit cost during the module manufacturing process.

[0013] The present disclosure also relates to providing a battery pack including such a battery module.

[0014] The technical problems to be solved by the present disclosure are not limited to the above problems, and those skilled in the art can clearly understand other problems not mentioned herein from the following description of the present disclosure.

[0015] Technical Solution

[0016] A battery module for solving the above problems according to the present disclosure may include: a battery cell assembly having a plurality of battery cells stacked on each other; a module housing that houses the battery cell assembly in an internal space; and a cover portion that is coupled to an outer surface of the module housing and has a barrier layer disposed between the module housing and the cover portion to block entry and exit of flames and reduce heat transfer, wherein the barrier layer may be foamed in the form of a foam and coupled to the cover portion and may be integrally formed with the cover portion.

[0017] The barrier layer may be disposed on an inner wall of the cover portion on a side facing the battery cell assembly in the cover portion.

[0018] The barrier layer may be a foam layer that is foamed to a preset thickness and coated on the inner wall of the cover portion.

[0019] The cover portion may be configured to cover an upper surface of the module housing, or cover the upper surface of the module housing and two side surfaces in a length direction of the module housing.

[0020] The cover portion may include: a first cover member that covers the upper surface of the module housing; and a pair of second cover members that cover two side surfaces in the length direction of the module housing.

[0021] The barrier layer may be disposed on an inner wall of the first cover member, or on inner walls of the first cover member and the second cover members.

[0022] One or more exhaust holes may be formed in the module housing, discharge slits communicating with the exhaust holes may be formed in the cover portion and the barrier layer, and the discharge slits may be formed simultaneously by pressing the cover portion and the barrier layer.

[0023] An adhesive layer may be interposed between the barrier layer and the module housing.

[0024] The barrier layer may include a polyurethane or silicone material.

[0025] The second cover member may be provided with at least one uneven portion formed by being recessed at regular intervals.

[0026] The second cover member may be formed with a coupling sleeve that is spaced apart by a thickness of the barrier layer and disposed along a length direction of the cover portion, and a jig that guides a shape of the barrier layer when the barrier layer is foamed in the form of a foam is detachably coupled to the coupling sleeve.

[0027] The battery cell assembly may be provided with a second barrier layer disposed between a plurality of battery cells and foamed and coated in the form of a foam.

[0028] The module housing may be provided with a third barrier layer that is foamed in the form of a foam and coated onto the upper surface of the battery cell assembly and the inner space of the module housing.

[0029] In addition, according to the present disclosure, a battery pack including the above-described battery module may be provided.

[0030] In addition, according to the present disclosure, a vehicle including the above-described battery pack may be provided.

[0031] Advantageous Effects

[0032] According to one aspect of the present disclosure, when the barrier layer is foamed in the form of a foam and coupled to the lid portion, when a thermal event occurs, the entry and exit of flames can be blocked, and heat transfer such as heat conduction and heat radiation can be minimized, thereby suppressing the propagation of flames between modules as much as possible and delaying the chain heat transfer.

[0033] In addition, according to one aspect of the present disclosure, when the barrier layer is integrally coupled to the lid portion, the adhesive layer between the existing lid portion and the barrier layer can be eliminated, so that the delamination structure of the lid portion can be simplified, and the lid portion can be relatively resistant to flames or high temperatures and have increased durability.

[0034] In addition, according to one aspect of the present disclosure, the additional lamination and stamping processes required for each component in the manufacturing process of the existing lid portion for blocking flames can be reduced. Therefore, the tact time during the module manufacturing process can be reduced, and the manufacturing unit cost can be reduced, thereby improving productivity.

[0035] In this way, according to the present disclosure, the entry and exit of flames from the trigger module including the trigger cell to the adjacent battery module can be blocked, and heat transfer such as heat conduction and heat radiation can be minimized, thereby delaying the heat propagation between the battery modules, thereby improving the safety of the battery modules.

[0036] In addition, the safety of the battery pack of the present disclosure is enhanced by including such a battery module. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The drawings illustrate preferred embodiments of the present disclosure and, together with the foregoing disclosure, are used to provide a further understanding of the technical features of the present disclosure. Therefore, the present disclosure is not to be construed as limited to the drawings.

[0038] Figure 1 is a schematic perspective view of a battery module according to an embodiment of the present disclosure.

[0039] Figure 2 is Figure 1 an exploded perspective view of the main configuration of a battery module.

[0040] Figure 3 is Figure 1 a longitudinal sectional view taken along line A - A’ in the battery module.

[0041] Figure 4 is Figure 3 an enlarged view of part B in

[0042] Figure 5 an exploded perspective view of a cover portion in a battery module according to an embodiment of the present disclosure.

[0043] Figure 6 is a view showing Figure 4 a cover portion that is a variant of the cover portion and is provided to cover the upper surface of the module housing.

[0044] Figure 7 is a view showing Figure 4 a variant of the cover portion.

[0045] Figure 8 is a view showing a cover portion in a battery module according to a second embodiment of the present disclosure.

[0046] Figure 9 is a view showing a cover portion in a battery module according to a third embodiment of the present disclosure.

[0047] Figure 10 is a longitudinal sectional view of a battery module according to a fourth embodiment of the present disclosure.

[0048] Figure 11 is a view for describing a battery pack according to an embodiment of the present disclosure.

[0049] Figure 12 is a view for describing a vehicle according to an embodiment of the present disclosure. Detailed Embodiments

[0050] Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Before the description, it should be understood that the terms used in the specification and the appended claims should not be construed as limited to the general and dictionary meanings, but should be interpreted based on the meanings and concepts corresponding to the technical aspects of the present disclosure on the basis of the principle that the inventor is allowed to appropriately define the terms for the best explanation.

[0051] Therefore, the description presented herein is only a preferred example for illustrative purposes only and is not intended to limit the scope of the present disclosure. Thus, it should be understood that other equivalent and modifications can be made thereto without departing from the scope of the present disclosure.

[0052] Figure 1 is a schematic perspective view of a battery module according to an embodiment of the present disclosure, and Figure 2 is Figure 1 an exploded perspective view of the main configuration of the battery module of

[0053] Referring to Figure 1 and Figure 2 , the battery module 10 according to the present disclosure includes a cell assembly 100, a module housing 200, and a cover portion 300.

[0054] The cell assembly 100 may include one or more battery cells 110. Here, each battery cell 110 may refer to a secondary battery. The battery cell 110 refers to a secondary battery including an electrode assembly, an electrolyte, and a pouch housing for accommodating the electrode assembly, and in this embodiment, a pouch-type battery cell 110 having a high energy density and being easy to stack is considered, but it is obvious that a cylindrical or square secondary battery may be used as the battery cell 110.

[0055] Mainly referring to Figure 2 , the pouch-type battery cell 110 includes an electrode assembly, a housing for accommodating the electrode assembly, and a pair of electrode leads 112 connected to the electrode assembly and led out from the housing to be used as electrode terminals. The pair of electrode leads 112 may be led out forward and backward (±Y direction) along the length direction of the battery cell 110. Alternatively, if necessary, the electrode leads 112 may have such a form that they are only located at one end in the Y-axis direction, for example, at the end in the -Y axis direction. Adjacent to the pair of electrode leads 112 of the battery cell 110, electrical components such as a bus bar 113 and a bus bar frame 114 may be provided, and a cell housing 111 may be further provided.

[0056] These battery cells 110 may be stacked and arranged in at least one direction. In this embodiment, mainly referring to Figure 2 , the battery cells 110 may be stacked in a form arranged along the horizontal direction (the width direction of the battery module 10, X-axis direction), while standing upright in the vertical direction (Z-axis direction) respectively.

[0057] The cell assembly 100 is an assembly of battery cells 110 formed by stacking a plurality of battery cells 110. That is to say, the cell assembly 100 may be an assembly of a plurality of pouch-type battery cells 110, where the wide surfaces of the battery cells 110 are upright and stacked in one direction (X-axis direction), as Figure 2 shown.

[0058] The module housing 200 can be configured to have an internal space formed therein and accommodate the battery cells 110 in the internal space. The module housing 200 is a component for protecting the cell assembly 100 from external impacts and the like, and can preferably be made of a material having excellent mechanical stiffness. The module housing 200 of this embodiment can include a housing body 210 and end plates 220 provided on the front and rear surfaces of the housing body 210.

[0059] The housing body 210 can be configured in a rectangular tubular form, which has open ends O at both ends in the length direction (Y-axis direction) and has a hollow structure with an empty interior. For example, the housing body 210 can be configured in a tubular form that has an upper surface, a lower surface, a left surface, and a right surface, and has openings formed at the front end and the rear end, respectively.

[0060] In addition, the module housing 200 can be formed in various other forms. For example, the housing body 210 can be configured in a form in which a left plate, a right plate, and a bottom plate are integrated with each other. In this case, the integrated housing portion can be referred to as a U-shaped frame. The U-shaped frame can be configured in a tubular form by welding a top plate to the upper surface. Alternatively, the module housing 200 can include a box-shaped lower housing in which a left plate, a right plate, a front plate, and a rear plate are integrated, and an upper cover that closes the upper open end of the lower housing.

[0061] The housing body 210 can be arranged to allow the cell assembly 100 to be inserted therein along the length direction. That is, the housing body 210 can be configured to allow the battery cells 110 stacked in multiple layers to be inserted therein in a sliding or press-fit manner. For the press-fit, the housing body 210 can be configured such that there is almost no gap between the upper and lower surfaces of the housing body 210 and the upper and lower ends of the battery cells 110, and there is almost no gap between the two side surfaces of the housing body 210 and both sides of the battery cells 110. The housing body 210 can be made of a metal material having rigidity and heat resistance to physically or chemically protect the accommodated battery cells 110.

[0062] The end plates 220 are provided at both ends in the length direction, i.e., the front end and the rear end, where the electrode leads of the battery cells 110 of the battery cell assembly 100 are located, and can be configured to be connected to the open end O of the housing body 210. In a state where the electrode leads of the battery cells 110 are fixedly connected to the bus bar frame, the end plates 220 can be provided to cover the bus bar frame, the electrode leads, the connection components, etc., so as not to be exposed to the outside. The end plates 220 are configured to be made of, for example, an insulating material inside and a metallic material outside, and can be configured to be fixedly connected to the housing body 210 by welding. At the same time, although not shown in the figure for convenience, the end plates 220 can have holes or slits partially for exposing components (such as the positive and negative terminals or connectors of the battery module 10) that need to be exposed to the outside.

[0063] The module housing 200 having such a structure can have exhaust holes H formed on at least one side. When discharging substances such as exhaust gas generated from the battery cell assembly 100 accommodated in the internal space, the exhaust holes H can be configured to allow the discharge substances to be discharged from the internal space of the module housing 200 to the outside. For example, in addition to the exhaust holes H, the module housing 200 can be configured in a sealed form. And, the exhaust holes H can be formed in a completely open form so as to penetrate the module housing 200 in the inward and outward directions.

[0064] In this embodiment, the exhaust holes H can be provided in the form of a long hole having a predetermined width in the width direction of the module housing 200 and extending in the length direction of the module housing 200. And, as shown by H in Figure 2 , the exhaust holes H can be formed in plural on the upper side of the module housing 200. At the same time, the number and shape of the exhaust holes H can be various, and if necessary, the positions where the exhaust holes H are provided can be changed differently.

[0065] The cover part 300 can be connected to the outer surface of the module housing 200. In this embodiment, the cover part 300 can be provided to cover the upper surface of the module housing 200 and the two side surfaces in the length direction of the module housing 200.

[0066] The cover part 300 can be provided to cover the upper surface of the module housing 200. Therefore, the cover part 300 can be configured to cover the exhaust holes H formed in the upper surface of the module housing 200. Additionally, the cover part 300 can be provided on both sides in the width direction (X-axis direction) of the module housing 200 (or both sides in the length direction (Y-axis direction)) to cover the two side surfaces of the module housing 200. Therefore, the cover part 300 can be connected to the outer surface (upper surface and two side surfaces) of the module housing 200.

[0067] The discharge slit 311 may be formed in the lid portion 300. The discharge slit 311 may be provided to communicate with the exhaust hole H.

[0068] Figure 3 is a longitudinal sectional view taken along line A-A' of the battery module, and Figure 1 is an enlarged view of part B in Figure 4 is Figure 3 .

[0069] In addition to the lid portion 300, it is necessary to effectively block, reduce, and delay the flames and high heat generated by a thermal event.

[0070] Referring to Figure 3 and Figure 4 and the foregoing Figure 2 , the lid portion 300 in this embodiment may have a barrier layer 400.

[0071] The barrier layer 400 may be provided on the inner wall of the lid portion 300 on the side facing the cell assembly 100 in the lid portion 300. Thus, the barrier layer 400 may be provided between the lid portion 300 and the module housing 200.

[0072] The barrier layer 400 may be foamed in the form of a foam and joined to the lid portion 300 and may be integrally formed with the lid portion 300. For example, the barrier layer 400 may be a foam layer that is foamed to a preset thickness and coated on the inner wall of the lid portion 300. The barrier layer 400 may be formed by directly foaming on the lid portion 300, and no connecting means such as an adhesive layer for bonding them is required between the barrier layer 400 and the lid portion 300.

[0073] However, an adhesive layer 350 may be interposed between the lid portion 300 including the barrier layer 400 and the module housing 200. The adhesive layer 350 is used to attach the lid portion 300 to the module housing 200.

[0074] A discharge slit 411 communicating with the exhaust hole H may be formed in the barrier layer 400. Thus, the discharge gas and the like generated in the battery module 10 can be easily discharged to the outside of the battery module 10 through the discharge slit 411 of the barrier layer 400 and the discharge slit 311 of the lid portion 300.

[0075] According to this embodiment, when the barrier layer 400 is foamed and joined to the lid portion 300, when a thermal event occurs, the entry and exit of flames can be blocked, and heat transfer such as heat conduction and heat radiation can be reduced and minimized.

[0076] In addition, according to this embodiment, when the barrier layer 400 foams and is integrally coupled to the cover part 300, the adhesive layer between the existing hierarchical structures of the cover part 300 (between the cover part 300 and the barrier layer 400) can be omitted, which will be described in detail later.

[0077] Figure 5 is an exploded perspective view of a cover part in a battery module according to an embodiment of the present disclosure.

[0078] Referring Figure 5 And referring again Figures 2 to 4 , the cover part 300 and the barrier layer 400 will be described in detail.

[0079] The cover part 300 is a component that is coupled to the outer surface (upper surface and two side surfaces) of the module housing 200 to delay heat transfer. To this end, the cover part 300 may include a first cover member 310 and a pair of second cover members 320.

[0080] The first cover member 310 may be a component that covers the upper surface of the module housing 200. Discharge slits 311 may be formed on the plate surface of the first cover member 310. The discharge slits 311 may be arranged to communicate with the exhaust hole H, and may be provided on the plate surface of the cover part 300 to correspond to the shape of the exhaust hole H. One or more bridges 312 may be provided in the discharge slits 311.

[0081] The second cover member 320 may be a component that covers the two side surfaces in the longitudinal direction of the module housing 200. The second cover member 320 may be arranged to bend vertically downward on both sides in the width direction (X-axis direction) of the module housing 200 (or on both sides in the longitudinal direction (Y-axis direction)). Therefore, the second cover member 320 may be arranged to cover the two side surfaces of the module housing 200.

[0082] The cover part 300 as described above may be made of a material that ensures fire resistance or heat resistance. Preferably, the fire-resistant layer may have a V-O rating or higher in the UL94 test. The fire-resistant layer may be made of an inorganic material (e.g., a flame retardant barrier (FRB) material, etc.), a mica material, a fire-resistant plastic, or a combination thereof. Therefore, when a thermal event occurs, the battery module 10 can ensure heat resistance to high-temperature emission substances (such as emission gases, flames, sparks, etc.) generated from adjacent battery modules. In addition, in the case where the battery module 10 includes a trigger cell, the external leakage of the internally generated emission substances may be delayed, or the heat transfer time to adjacent modules may be delayed. On the other hand, obviously, any material that ensures fire resistance or heat resistance other than the above materials can be used as the material of the fire-resistant layer.

[0083] As described above, the barrier layer 400 may be integrally provided with the cover part 300 by foaming in the form of a foam and being coupled to the cover part 300, and may be a foam layer that is foamed to a preset thickness and coated on the inner wall of the cover part 300. Referring mainly to Figure 5 , the foam layer may be coupled to the inner wall of the first cover member 310 of the cover part 300.

[0084] The barrier layer 400 may include a polyurethane or silicone material. Due to the material of the barrier layer 400, the entry and exit of flames can be blocked, and heat transfer such as heat conduction and heat radiation can be minimized.

[0085] In addition, since the barrier layer 400 is composed of a foam layer, due to the particulate structure characteristics of the foam layer, minute air layers are included inside the layer, which can buffer external impacts and mitigate and absorb external forces or impacts. In addition, the barrier layer 400 is foamed in the form of a foam to form a layer and occupies space, which can result in a lighter weight compared to other materials.

[0086] In the barrier layer 400, a discharge slit 411 communicating with the exhaust hole H may be formed, as in the cover part 300. A bridge 412 may be provided in the discharge slit 411.

[0087] The discharge slit 411 may be formed by pressing the cover part 300 and the barrier layer 400 simultaneously. That is, in the manufacturing process of the existing cover part, each component requires an additional lamination and stamping process, and thus, the lamination and stamping processes of the cover part 300 and the barrier layer 400 should be performed separately and individually, and the complex process results in an increase in the cycle time during the manufacturing process, an increase in the manufacturing unit cost, and inevitably a reduction in productivity.

[0088] According to this embodiment, since the barrier layer 400 is integrally formed with the cover part 300 by foaming in the form of a foam and being coupled to the cover part 300, a separate lamination process is not required. The adhesive layer between the layered structures of the existing cover part can be omitted, so that the layered structure of the cover part 300 can be simplified, and the cover part 300 can be relatively resistant to flames or high temperatures and have increased durability. The phenomenon that the adhesive layer is melted by the flame or high heat and the layered structure of the cover part 300 itself is separated and peeled off can be reduced.

[0089] In addition, since the barrier layer 400 is integrally formed with the cover part 300, the discharge slits 311, 411 of the cover part 300 and the barrier layer 400 can be processed simultaneously using only one integral stamping operation without a separate pressing process for forming the discharge slits 311, 411. Therefore, the cycle time during the module manufacturing process can be reduced, and the manufacturing unit cost can be lowered, thereby improving productivity.

[0090] According to this embodiment, the fire resistance or heat resistance of the upper surface and the two side surfaces of the module housing 200 can be ensured by the cover portion 300. In addition, the barrier layer 400 is foamed in the form of foam and connected to the cover portion 300, and thus, when a thermal event occurs, the entry and exit of flames can be blocked and heat transfer such as heat conduction and heat radiation can be minimized, thereby suppressing the flame propagation between modules as much as possible and delaying the chain heat transfer.

[0091] Figure 6 is a view showing a cover portion that is a modified example of Figure 4 and is provided to cover the upper surface of the module housing, and Figure 7 is a view showing Figure 4 a modified example of the cover portion.

[0092] Referring to Figure 6 , as a modified example of the cover portion 300, the cover portion 300a can be provided to cover only the upper surface of the module housing 200. The cover portion 300a can be provided in a flat plate type corresponding to the upper plate region of the module housing 200. And, in this embodiment, the cover portion 300a is not provided with the second cover member 320 that covers the two side surfaces of the module housing 200, and the cover portion 300a can be provided only on the upper surface of the module housing 200. And, the barrier layer 400 can be provided on the lower wall of the cover portion 300a.

[0093] Referring to Figure 7 , as a modified example of the barrier layer 400, the cover portion 300 includes the first cover member 310 and the second cover member 320. And, the barrier layer 400 can be provided not only on the inner wall of the first cover member 310 but also on the inner wall of the second cover member 320. That is, the barrier layer 400 can be connected to the inner wall of the cover portion 300, which is composed of the inner wall of the first cover member 310 that covers the upper surface of the module housing 200 and the inner walls of the pair of second cover members 320 that cover the two side surfaces in the longitudinal direction of the module housing 200. According to this modified example, the flame blocking performance and the heat transfer efficiency can be relatively higher than those of the previous embodiment.

[0094] In these modified examples, when the sizes of the battery module 10 and the battery pack 1 (see Figure 11 ) change, any one of the embodiments can be applied as needed.

[0095] In this way, the barrier layer 400 foams in the form of a foam and is connected to the cover parts 300 and 300a. Therefore, when a thermal event occurs, the entry and exit of the flame can be blocked, and heat transfer such as heat conduction and heat radiation can be minimized, thereby suppressing the flame propagation between modules as much as possible and delaying the chain heat transfer.

[0096] In addition, according to this embodiment, since the barrier layer 400 foams and is integrally connected to the cover part 300a, the adhesive layer between the lamination structures of the existing cover part 300 can be omitted, so that the lamination structure of the cover part 300a can be simplified, and the cover part 300a can be relatively resistant to flames or high temperatures and has increased durability.

[0097] In addition, the additional lamination and stamping processes required for each component in the manufacturing process of the existing cover part for blocking flames can be reduced. Therefore, the tact time during the module manufacturing process can be reduced, and the manufacturing unit cost can be reduced, thereby improving productivity.

[0098] Next, other embodiments of the battery module 10 of the present disclosure will be briefly described with reference to Figures 8 to 10 Briefly describe other embodiments of the battery module 10 of the present disclosure.

[0099] Figure 8 is a view showing the cover part in the battery module according to the second embodiment of the present disclosure, Figure 9 is a view showing the cover part in the battery module according to the third embodiment of the present disclosure, and Figure 10 is a longitudinal sectional view of the battery module according to the fourth embodiment of the present disclosure.

[0100] The same reference numerals in the foregoing drawings refer to the same components, and the repeated description of the same components will be omitted, and the differences from the above embodiments will be mainly described.

[0101] Referring to Figure 8 , the cover part 300b includes a first cover member 310 covering the upper surface of the module housing 200 and a pair of second cover members 320b covering two side surfaces in the longitudinal direction of the module housing 200, and the barrier layer 400 can be provided on the inner wall of the first cover member 310. And, at least one uneven part 330 formed by being recessed at regular intervals can be provided on the second cover member 320b.

[0102] The uneven part 330 can be provided in the area where the barrier layer 400 faces the second cover member 320b, and can be formed by being recessed at regular intervals in the thickness direction of the second cover member 320b.

[0103] According to the present embodiment, the coupling force of the barrier layer 400 to the cover portion 300b can be further improved. That is, the barrier layer 400 is integrally coupled to the cover portion 300b in the form of foam, and the edge of the barrier layer 400 is filled and hardened to correspond to the shape of the uneven portion 330, so that the barrier layer 400 can be more firmly coupled to the cover portion 300b. The barrier layer 400 can be more integrally coupled to the cover portion 300b. Therefore, even when exposed to a flame or high temperature during a thermal event, the peeling phenomenon of the barrier layer 400 from the cover portion 300b can be minimized. The layered structure of the cover portion 300b including the barrier layer 400 can be relatively more resistant to a flame or high temperature and has increased durability.

[0104] Referring to Figure 9 , the cover portion 300c of the battery module 10 according to the third embodiment includes a first cover member 310 that covers the upper surface of the module housing 200 and a pair of second cover members 320c that cover both side surfaces in the length direction of the module housing 200, and the barrier layer 400 can be provided on the inner wall of the first cover member 310. And, a coupling sleeve 340 to which the fixture 70 is detachably coupled can be formed on the second cover member 320c.

[0105] Specifically, the barrier layer 400 can be a foam layer coated on the inner wall of the cover portion 300c, and the foam layer must be controlled to be formed with a preset thickness. Therefore, a separate guide or fixture 70 structure for controlling the thickness of the foam layer may be required. Accordingly, the second cover member 320c can be formed with a coupling sleeve 340 that is provided to be spaced apart by the thickness of the barrier layer 400 and is provided along the length direction of the cover portion 300c. After the fixture 70 is coupled to the coupling sleeve 340 formed along the length direction of the cover portion, the barrier layer 400 can be foamed in the gap formed by the fixture 70 and the first cover member 310 in the form of foam. In this case, the shape of the barrier layer 400 can be guided, and the barrier layer 400 having a preset thickness can be easily formed. After coupling the barrier layer 400, the fixture 70 can be removed.

[0106] Referring to Figure 10 , in the battery module 10 according to the fourth embodiment, the battery cell assembly 100 can be provided with a second barrier layer 420 that is provided between the plurality of battery cells 110 and is foamed and coated in the form of foam.

[0107] Further, the module housing 200 may be provided with a third barrier layer 430, which is foamed in the form of a foam and coated on the upper surface of the battery cell assembly 100 and the internal space of the module housing 200. Thus, when the foam layer made of polyurethane or silicone material covers each battery cell 110 inside the battery module, the entry and exit of flames can be blocked, and heat transfer such as heat conduction and heat radiation can be minimized, so that when a thermal event occurs, the flame propagation efficiency between modules can be improved and the chain heat transfer can be delayed as much as possible.

[0108] Figure 11 is a view for describing a battery pack according to an embodiment of the present disclosure, and Figure 12 is a view for describing a vehicle according to an embodiment of the present disclosure.

[0109] Referring to Figure 11 , the battery pack 1 according to the present disclosure may include one or more of the above-described battery modules 10 according to the present disclosure. In particular, in order to increase the capacity and / or output power, the battery pack 1 according to the present disclosure may include a plurality of battery modules 10 according to the present disclosure. In this case, the above various configurations may be applied to each battery module 10. For example, each battery module 10 may include a battery cell assembly 100, a module housing 200, and a cover portion 300, and the cover portion 300 may include a barrier layer 400. The barrier layer 400 may be made of a foam layer made of polyurethane or silicone material to easily block flames and heat transfer. And, these multiple battery modules 10 may be accommodated inside the battery pack housing 50. In addition, in the case of the battery module 10 according to an embodiment of the present disclosure, even if another battery module 10 is located on the front side or the rear side, heat transfer between the modules can be effectively prevented.

[0110] In addition to the battery module 10 or the battery pack housing, the battery pack 1 according to the present disclosure may further include various other components in the internal space of the battery pack housing, such as components of a battery pack known when applying the present disclosure, such as a battery management system (BMS), a bus bar, a relay, a current sensor, a fuse, etc.

[0111] Referring to Figure 12 , the battery module 10 according to the present disclosure or the battery pack 1 according to the present disclosure may be applied to a vehicle V, such as an electric vehicle or a hybrid vehicle. That is, the vehicle V according to the present disclosure may include the battery module 10 according to the present disclosure or the battery pack 1 according to the present disclosure. Additionally, in addition to the battery module 10 or the battery pack 1, the vehicle V according to the present disclosure may further include various other components included in the vehicle V. For example, in addition to the battery module 10 according to the present disclosure, the vehicle V according to the present disclosure may further include a vehicle body, a motor, control devices such as an electronic control unit (ECU), etc.

[0112] In addition, the battery module 10 according to the present disclosure or the battery pack 1 according to the present disclosure can be applied to an energy storage system ESS. That is, the energy storage system according to the present disclosure can include the battery module 10 according to the present disclosure or the battery pack 1 according to the present disclosure.

[0113] The present disclosure has been described above with respect to a limited number of embodiments and drawings, but the present disclosure is not limited thereto, and various modifications and variations can be made by those of ordinary skill in the technical field to which the present disclosure pertains within the scope of the technical aspects of the present disclosure and the appended claims and their equivalents.

[0114] Meanwhile, the terms indicating directions used herein (such as up, down, left, right, front, and back) are used only for the purpose of facilitating description, and it is obvious to those skilled in the art that the terms can be changed according to the position of the element or the observer.

[0115] [Explanation of Reference Numerals]

[0116] 1: Battery pack V: Vehicle

[0117] 10: Battery module 100: Cell assembly

[0118] 110: Battery cell 200: Module housing

[0119] 210: Housing body H: Exhaust hole

[0120] 220: End plate 300, 300a, 300b, 300c: Cover portion

[0121] 310: First cover member 311: Discharge slit

[0122] 320, 320b, 320c: Second cover member 330: Uneven portion

[0123] 340: Coupling sleeve 350: Adhesive layer

[0124] 400: Barrier layer

Claims

1. A battery module, the battery module comprising: a cell assembly having a plurality of battery cells stacked on one another; a module housing that houses the cell assembly in an internal space; and a cover portion coupled to an outer surface of the module housing and having a barrier layer disposed between the module housing and the cover portion to block entry and exit of flames and reduce heat transfer, wherein the barrier layer is foamed in the form of a foam and coupled to the cover portion and integrally formed with the cover portion.

2. The battery module according to claim 1, Among them, wherein the barrier layer is disposed on an inner wall of the cover portion on a side facing the cell assembly in the cover portion.

3. The battery module according to claim 2, Among them, wherein the barrier layer is a foam layer foamed to a preset thickness and coated on the inner wall of the cover portion.

4. The battery module according to claim 2, Among them, wherein the cover portion is configured to cover an upper surface of the module housing, or cover the upper surface of the module housing and two side surfaces in a length direction of the module housing.

5. The battery module according to claim 4, Among them, wherein the cover portion includes: a first cover member that covers the upper surface of the module housing; and a pair of second cover members that cover two side surfaces in the length direction of the module housing.

6. The battery module according to claim 5, Among them, wherein the barrier layer is disposed on an inner wall of the first cover member, or on inner walls of the first cover member and the second cover members.

7. The battery module according to claim 3, Among them, wherein one or more exhaust holes are formed in the module housing, emission slits communicating with the exhaust holes are formed in the cover portion and the barrier layer, and the emission slits are formed simultaneously by pressing the cover portion and the barrier layer.

8. The battery module according to claim 3, Among them, wherein an adhesive layer is interposed between the barrier layer and the module housing.

9. The battery module according to claim 3, Among them, wherein the barrier layer includes a polyurethane or silicone material.

10. The battery module according to claim 5, Among them, wherein the second cover member is provided with at least one uneven portion formed by being recessed at regular intervals.

11. The battery module according to claim 5, Among them, wherein the second cover member forms a coupling sleeve that is spaced apart by a thickness of the barrier layer and disposed along a length direction of the cover portion, and a jig for guiding a shape of the barrier layer when the barrier layer is foamed in the form of a foam is detachably coupled to the coupling sleeve.

12. The battery module according to claim 3, Among them, wherein the cell assembly is provided with a second barrier layer disposed between the plurality of battery cells and foamed and coated in the form of a foam.

13. The battery module according to claim 12, Among them, wherein the module housing is provided with a third barrier layer foamed and coated on an upper surface of the cell assembly and an internal space of the module housing.

14. A battery pack, the battery pack including the battery module according to any one of claims 1 to 13.

15. A vehicle, the vehicle including the battery pack according to claim 14.

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