Battery module and battery pack including same

Abstract

The battery module of the present disclosure includes: a battery cell stack including a plurality of battery cells; a module frame including a bottom portion and two side portions facing each other, and housing a stack of battery cells therein; a thermally conductive resin layer provided between one surface of the module frame and the battery cell stack; a pad provided at at least one end of one surface of the module frame; and a reinforcing material disposed between the battery cell stack and the pad, in which the reinforcing material fills a space between the battery cell stack and the pad.

Description

Technical Field

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Korean Patent Application No. 10-2023-0107114, filed on August 16, 2023, and Korean Patent Application No. 10-2024-0097888, filed on July 24, 2024, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference in their entirety.

[0003] The present disclosure relates to a battery module and a battery pack including the same, and more particularly, to a battery module that prevents overflow of a thermally conductive resin and a battery pack including the same. Background Art

[0004] Secondary batteries, highly suitable for a wide range of products and exhibiting excellent electrical properties such as high energy density, are commonly used not only in portable devices but also in electric and hybrid electric vehicles powered by electrical energy sources, as well as energy storage systems. These secondary batteries have attracted attention due to their significant advantages, such as significantly reducing fossil fuel use and not generating byproducts from energy use, making them a new environmentally friendly and energy-saving energy source.

[0005] Small mobile devices use one, two, or three battery cells per device, while medium-sized or large devices such as vehicles require high power and large capacity. Therefore, medium-sized or large battery modules with multiple battery cells electrically connected to each other are used.

[0006] Since medium-sized or large-sized battery modules are preferably manufactured to have the smallest possible size and weight, prismatic batteries, pouch-type batteries, and the like, which can be stacked with a high degree of integration and have a small weight relative to their capacity, are primarily used as battery cells for medium-sized or large-sized battery modules. On the other hand, a battery module may include a module frame having open front and rear surfaces, and may house a battery cell stack within an internal space to protect the battery cell stack from external impact, heat, or vibration.

[0007] Figure 1 is an exploded perspective view showing a conventional battery module.

[0008] Figure 2 This is a three-dimensional view of a conventional battery cell stack viewed from below.

[0009] Figure 3 It shows Figure 1 A cross-sectional view of the battery module taken along the YZ plane.

[0010] Figure 4 It shows Figure 3An enlarged cross-sectional view of a portion of .

[0011] Refer to it together Figure 1 and Figure 2 The conventional battery module 100C includes a battery cell stack 12 including a plurality of battery cells 11 and a module frame 30 in which the battery cell stack 12 is accommodated. The battery cell stack 12 may further include a compression pad 10 disposed between the plurality of battery cells 11, such as Figure 3 shown.

[0012] The battery module 100C may also include an upper plate (not shown) coupled to the module frame 30 and covering the upper portion of the battery cell stack 12, end plates (not shown) respectively located on the front and rear surfaces of the battery cell stack 12, and a bus bar frame 13 located between the battery cell stack 12 and the end plates (not shown).

[0013] The conventional module frame 30 includes a bottom portion 30a and two side portions 30b facing each other. The bottom portion 30a may have a shape with its front and rear surfaces open along the X-axis and its upper portion open along the Z-axis. The side portions 30b may extend from both sides of the bottom portion 30a in the Z-axis direction. The bottom portion 30a and the side portions 30b form a space for accommodating the battery cell stack 12.

[0014] Meanwhile, before the battery cell stack 12 is mounted on the module frame 30, a thermally conductive resin layer 31 may be formed between the module frame 30 and the battery cell stack 12. The thermally conductive resin layer 31 may be used to transfer heat generated from the battery cell stack 12 to the outside of the battery module and secure the battery cell stack within the battery module.

[0015] The thermally conductive resin layer 31 can be formed by applying and curing a thermally conductive resin layer to the bottom 30a of the module frame 30. When applying the thermally conductive resin, pads 32 can be placed on the bottom 30a to prevent the thermally conductive resin from overflowing outside the desired area. Pads 32 are placed at both ends of the bottom 30a to control the direction of thermally conductive resin application. However, during the thermally conductive resin spreading process, it may extend beyond the pads 32 and spread to areas other than the application area.

[0016] Refer to it together Figure 3 and Figure 4 After the battery cell stack 12 is mounted on the module frame 30, an incompletely filled space SP exists between the gasket 32 and the battery cell stack 12. During the coating process, the thermally conductive resin may overflow from the gasket 32 through this space SP. In this case, the battery cell stack 12 may be damaged, the performance of the battery cell stack 12 may deteriorate, and safety issues may arise.

[0017] Therefore, it is necessary to develop a structure that can control the overflow of the thermally conductive resin during the molding process of the thermally conductive resin layer. Summary of the Invention

[0018] Technical issues

[0019] An object of the present disclosure is to provide a battery module that prevents overflow of a thermally conductive resin and a battery pack including the same.

[0020] However, the objects of the embodiments of the present disclosure are not limited to those disclosed above, and can be expanded in various ways within the scope of the technical concept included in the present disclosure.

[0021] Technical Solution

[0022] According to one aspect of the present disclosure, a battery module is provided, comprising: a battery cell stack including a plurality of battery cells; a module frame including a bottom and two sides facing each other, and accommodating the battery cell stack; a thermally conductive resin layer disposed between one surface of the module frame and the battery cell stack; a pad disposed on at least one end portion of one surface of the module frame; and a reinforcing material disposed between the battery cell stack and the pad, wherein the reinforcing material fills a space between the battery cell stack and the pad.

[0023] In one embodiment, one surface may be an upper surface of the base.

[0024] In one embodiment, one surface may be an inner surface of the side portion.

[0025] In one embodiment, the reinforcement material may comprise a resin.

[0026] In one embodiment, the thermally conductive resin layer may not overflow to the outside of the pad and the reinforcing material.

[0027] In one embodiment, the reinforcing material may be first disposed on one surface of the battery cell stack in an uncured state and then formed to be compressed and cured between the battery cell stack and the mat when the battery cell stack is accommodated in the module frame.

[0028] In one embodiment, the reinforcement material may be polyurethane foam (PU foam).

[0029] In one embodiment, the reinforcing material may be silicone.

[0030] In one embodiment, a plurality of pads may be provided at both ends of one surface of the module frame, and a thermally conductive resin layer may be provided between the pads.

[0031] According to another aspect of the present disclosure, a battery pack including the above-mentioned battery module is provided.

[0032] Beneficial effects

[0033] The battery module of the present disclosure includes a reinforcing material filling a space between a battery cell stack and a gasket, and thus when the battery cell stack is inserted into a module frame, it is possible to prevent a thermally conductive resin from flowing into an unintended space. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 is an exploded perspective view showing a conventional battery module.

[0035] Figure 2 This is a three-dimensional view of a conventional battery cell stack viewed from below.

[0036] Figure 3 It shows Figure 1 A cross-sectional view of the battery module taken along the YZ plane.

[0037] Figure 4 It shows Figure 3 An enlarged cross-sectional view of a portion of .

[0038] Figure 5 is a plan view showing a battery pack according to an embodiment.

[0039] Figure 6 is an exploded perspective view showing a battery module according to an embodiment.

[0040] Figure 7 Is shown in combination Figure 6 A combined three-dimensional view of a battery module with components shown in FIG.

[0041] Figure 8 yes Figure 6 A three-dimensional image of the battery module viewed from below.

[0042] Figure 9 It shows Figure 7 A cross-sectional view of the battery module taken along the YZ plane.

[0043] Figure 10 It shows Figure 9 An enlarged cross-sectional view of a portion of . DETAILED DESCRIPTION

[0044] Hereinafter, various embodiments of the present disclosure will be described in detail with reference to the accompanying drawings to the extent that a person skilled in the art can easily practice the present disclosure. The present disclosure can be implemented in various forms and is not limited to the embodiments described herein.

[0045] In order to clearly describe the present disclosure, descriptions of parts not related to the description of the present disclosure will be omitted, and the same or similar components will be denoted by the same reference numerals throughout the specification.

[0046] Since the drawings arbitrarily illustrate the sizes and thicknesses of various components for ease of description, the present disclosure is not necessarily limited to what is shown. The drawings depict thicknesses at an exaggerated scale to clearly illustrate different layers and regions. In addition, the drawings exaggerate the thickness of specific layers or regions to facilitate their description.

[0047] When a layer, film, region, plate, etc. is positioned "on" a specific portion, this description includes not only the case where the layer, film, region, plate, etc. is positioned "directly" on the specific portion, but also the case where the layer, film, region, plate, etc. is positioned on the specific portion via another portion. When one portion is positioned "directly" on another portion, this means that no new component exists between the two portions. Furthermore, when a component is positioned "on" a reference portion, this means that the component exists on top of or below the reference portion, and does not necessarily mean that the component is positioned only on the top portion of the reference portion, opposite to the direction of gravity.

[0048] Throughout the specification herein, when a specific part “includes” a component, unless otherwise defined, this does not mean that the specific part excludes other components but means that the part may further include other components.

[0049] Throughout the specification herein, the term “in a plan view” means viewing an object from above, and the term “in a cross-sectional view” means viewing a vertical cross-section of an object from the side.

[0050] Figure 5 is a plan view showing a battery pack according to an embodiment.

[0051] Reference Figure 5 According to an embodiment, a battery pack 1000 includes battery modules 100, a pack frame 1100, a busbar assembly 1200, a BDU (battery disconnect unit) module 1300 for controlling electrical connections of the battery modules 100, and a BMS (battery management system) module 1400 for monitoring and controlling the operation of the battery modules 100. According to this embodiment, at least one busbar assembly 1200 electrically connects at least one of the following: between battery modules 100, between a battery module 100 and a BDU module 1300, between a battery module 100 and a BMS module 1400, and between a BDU module 1300 and a BMS module 1400. Specifically, multiple battery modules 100 can be housed in the pack frame 1100, and the busbar assembly 1200 can be used to electrically connect the battery modules 100 or between the battery modules 100 and the BDU module 1300. That is, the busbar assembly 1200 according to this embodiment can provide a high voltage (HV) connection. Here, the HV connection refers to a connection serving as a power source requiring high voltage power supply, for example, a connection between battery cells or a connection between battery modules.

[0052] Meanwhile, the BDU module 1300 is a component that controls the electrical connection of the battery module 100. For example, it can cut off the power supply between the power converter and the battery module 100. If the current exceeds a set range, the BDU module 1300 can cut off the power supply to the battery pack 1000 to ensure the safety of the battery pack 1000.

[0053] At the same time, the low voltage (LV) connection member 1200' according to the present embodiment can be electrically connected between the battery module 100 and the BMS module 1400. Here, the electrical connection refers to the LV connection representing a sensing connection for detecting and controlling the voltage and temperature of the battery module 100. Specifically, sensors and the like are provided in the battery module 100, and the temperature or voltage information of the battery module 100 is transmitted to the BMS module 1400 in real time via the LV connection member 1200'. The operating status of the battery module 100 can be monitored and controlled in real time from the BMS module 1400. Although not specifically shown, the HV current sensor can be integrated in the BMS module 1400. In this case, the bus bar assembly according to the present embodiment can be electrically connected between the battery module 100 and the BMS module 1400 or between the BDU module 1300 and the BMS module 1400.

[0054] The following will refer to Figures 6 to 10 However, each battery module 100 described below is an exemplary structure of a battery module including a battery cell stack 120 , to which various types of battery modules each including a battery cell stack 120 may be applied.

[0055] Figure 6 is an exploded perspective view showing a battery module according to an embodiment.

[0056] Figure 7 Is shown in combination Figure 6 A combined three-dimensional view of a battery module with components shown in FIG.

[0057] Figure 8 yes Figure 6 A three-dimensional image of the battery module viewed from below.

[0058] Figure 9 It shows Figure 7 A cross-sectional view of the battery module taken along the YZ plane.

[0059] Figure 10 It shows Figure 9 An enlarged cross-sectional view of a portion of .

[0060] Refer to it together Figure 6 and Figure 7The battery module 100 according to the present embodiment includes a battery cell stack 120 including a plurality of battery cells 110 and a module frame 300 in which the battery cell stack 120 is accommodated. Figure 6 As shown, the battery cell stack 120 includes a plurality of battery cells 110 stacked in one direction, for example, the plurality of battery cells 110 may be stacked in the Y-axis direction. The battery cells 110 may be soft-pack type battery cells, but the embodiments of the present disclosure are not limited thereto. At the same time, the battery cell stack 120 may further include a compression pad 111 disposed between the plurality of battery cells 110, such as Figure 9 The compression pad 111 includes expansion foam or the like, and thus can absorb the expansion of the battery cell 110 and improve the structural stability of the battery module 100 .

[0061] The battery module 100 may further include an upper plate 400 coupled to the module frame 300 and covering an upper portion of the battery cell stack 120 , end plates 150 respectively located on the front and rear surfaces of the battery cell stack 120 , and a bus bar frame 130 located between the battery cell stack 120 and the end plates 150 .

[0062] The battery module 100 includes a thermally conductive resin layer 310 located between the battery cell stack 120 and the module frame 300. The thermally conductive resin layer 310 may be a thermally conductive adhesive. Various organic resins and / or inorganic resins such as thermally conductive epoxy adhesives, thermally conductive silicone adhesives, and thermally conductive polyurethane adhesives may be used as thermally conductive adhesives. The thermally conductive resin layer 310 may be used to adhesively fix the battery cell stack 120 within the battery module 100. In addition, since the thermally conductive resin layer 310 has a higher thermal conductivity than conventional adhesives, it may further increase the amount and speed of heat transfer between the battery cell stack 120 and the module frame 30, and may be used as a heat dissipation layer that transfers heat generated from the battery cell stack 120 to the outside of the battery module 100. The thermally conductive resin layer 310 is disposed between the battery cell stack 120 and one surface of the module frame 300.

[0063] The module frame 300 may have a shape with open upper, front, and rear surfaces. The module frame 300 may be a U-shaped frame. When the two open sides of the module frame 300 are referred to as a first side and a second side, respectively, the module frame 300 is formed of a plate-like structure that is folded to continuously surround the front, lower, and rear surfaces of the remaining outer surfaces of the battery cell stack 120, excluding the surfaces corresponding to the first and second sides. The upper surface of the module frame 300 is open, facing the lower surface.

[0064] The pad 320 is disposed on one surface of the module frame 300 and may guide a coating position of the thermally conductive resin during the molding process of the thermally conductive resin layer 310 .

[0065] The module frame 300 includes a bottom 300a and two side portions 300b facing each other. As described above, the thermally conductive resin layer 310 is provided between one surface of the module frame 300 and the battery cell stack 120. The one surface of the module frame 300 may be the upper surface of the bottom 300a or the inner surface of the side portion 300b. The upper surface of the bottom 300a may be the surface facing the lower surface of the battery cell stack 120. The inner surface of the side portion 300b may be the surface facing the front and rear surfaces of the battery cell stack 120. In an embodiment, the thermally conductive resin layer 310 may be provided between the upper surface of the bottom 300a of the module frame 300 and the battery cell stack 120. Alternatively, in another embodiment, the thermally conductive resin layer 310 may be provided between the inner surface of the side portion 300b of the module frame 300 and the battery cell stack 120.

[0066] Hereinafter, as an example, the thermally conductive resin layer 310 is described as being disposed on the upper surface of the bottom 300a of the module frame 300. That is, a structure in which the thermally conductive resin layer 310, the pad 320, and the reinforcing material RS described below are disposed on the bottom 300a will be described as an example.

[0067] However, the embodiments of the present disclosure are not limited thereto, and the thermally conductive resin layer 310 may be provided on the inner surface of the side portion 300b instead of the bottom portion 300a. In this case, the description of the relationship between the thermally conductive resin layer 310, the pad 32, and the reinforcing material RS described below also applies.

[0068] In the examples, reference Figure 6 The thermally conductive resin layer 310 is formed by coating the bottom portion 300 a long in the X-axis direction (the extending direction of the bottom portion 300 a ).

[0069] The pad 320 is provided at at least one end of the bottom 300a. For example, the pad 320 may be provided at both ends of the bottom 300a to guide the location of the thermally conductive resin coating during the molding process of the thermally conductive resin layer 310 or to prevent the thermally conductive resin from overflowing to the outside of the pad 320. Figure 6 , the pads 320 are shown as being formed one by one on each end of the bottom portion 300a. However, the size, position, and number of the pads 320 may be modified and designed in consideration of the amount of thermally conductive resin applied. The pads 320 may have insulating properties. Furthermore, when the battery cell stack 120 is inserted into the module frame 300, the pads 320 may be made of a material such as polyurethane foam (PU foam) or rubber so that the pads 320 can be compressed and contact the bottom surface of the battery cell stack 120.

[0070] The upper plate 400 has a single plate structure that covers the remaining upper surfaces except for the front, lower, and rear surfaces covered by the module frame 300. The module frame 300 and the upper plate 400 can be joined by welding or the like with corresponding corner regions in contact with each other, thereby forming a structure that covers the battery cell stack 120. In other words, the module frame 300 and the upper plate 400 can form joint portions CP at corresponding corners by a joining method such as welding.

[0071] Refer to it together Figure 6 、 Figure 8 、 Figure 9 and Figure 10 , the reinforcing material RS is provided between the battery cell stack 120 and the pad 320 of the embodiment. To illustrate the position where the reinforcing material RS is formed, Figure 8 The pad 320 is omitted. The reinforcing material RS may be provided along the Y-axis direction which is the extending direction of the pad 320. When the battery cell stack 120 is accommodated in the module frame 300, the reinforcing material RS fills the space SP between the battery cell stack 120 and the pad 320 (see FIG. Figure 3 ). Space SP (see Figure 3 ) represents the gap between the battery cell stack 120 and the pad 320. The reinforcing material RS can prevent the thermally conductive resin layer 310 from passing through the space SP (see Figure 3 ) Overflow pad 320.

[0072] The reinforcing material RS may include a resin. For example, the reinforcing material RS may be a polyurethane foam (PU foam) formed by spraying a polyurethane spray or the like on one surface (e.g., the lower surface) of the battery cell stack 120. Alternatively, the reinforcing material RS may be a silicone resin formed on one surface (e.g., the lower surface) of the battery cell stack 120 using a silicone gun or the like. However, the material of the reinforcing material RS is not limited to those described above, and any material may be used as long as it has insulating properties and a predetermined compressibility.

[0073] The reinforcing material RS may be first provided on one surface (e.g., the lower surface) of the battery cell stack 120 in an uncured state, and then formed to be compressed and cured between the battery cell stack 120 and the gasket 320 when the battery cell stack 120 is accommodated in the module frame 300. The reinforcing material RS may fill the space SP between the battery cell stack 120 and the gasket 320 in the compression process (see Figure 3 ).

[0074] The battery module 100 of the present disclosure includes a reinforcing material RS disposed between the battery cell stack 120 and the gasket 320 disposed on the bottom 300a of the module frame 300. This fills the space between the battery cell stack 120 and the gasket 320 with the reinforcing material RS and effectively controls the overflow of the thermally conductive resin. Consequently, defects in the battery module 100 caused by the thermally conductive resin layer 310 being molded in an undesirable portion can be prevented.

[0075] In the above embodiments, expressions representing directions such as "front", "back", "left", "right", "up" and "down" are used, but these expressions are used only for convenience of description and may vary, for example, depending on the position of the target object or observer.

[0076] One or more battery modules according to the embodiments of the present disclosure described above may be installed together with various control and protection systems such as a battery management system (BMS), a battery disconnect unit (BDU), and a cooling system to form a battery pack.

[0077] The battery module or battery pack can be applied to various devices, for example, transportation vehicles including electric bicycles, electric vehicles and hybrid vehicles, and energy storage systems (ESS). However, not limited thereto, the battery module or battery pack can be applied to various devices using secondary batteries.

[0078] Although the embodiments of the present disclosure have been described in detail, the technical scope of the present disclosure is not limited to the embodiments and also includes various modifications and improvements made by those having ordinary skill in the art using the concepts defined in the appended claims.

[0079] [Explanation of Reference Numerals]

[0080] 100: Battery module

[0081] 120: Battery cell stack

[0082] 110: Battery cell

[0083] 111: Compression pad

[0084] 300: Module Framework

[0085] 300a: bottom

[0086] 300b: Side

[0087] 310: Thermal conductive resin layer

[0088] 320: Pad

[0089] 400: On the board

[0090] RS: Reinforced Material

Claims

1. A battery module comprising: a battery cell stack, the battery cell stack comprising a plurality of battery cells; a module frame including a bottom and two sides facing each other, and housing the battery cell stack therein; a thermally conductive resin layer disposed between one surface of the module frame and the battery cell stack; a pad disposed on at least one end portion of the one surface of the module frame; as well as a reinforcing material disposed between the battery cell stack and the mat, The reinforcing material fills the space between the battery cell stack and the pad.

2. The battery module according to claim 1, wherein: The one surface is an upper surface of the bottom.

3. The battery module according to claim 1, wherein: The one surface is an inner surface of the side portion.

4. The battery module according to claim 1, wherein: The reinforcing material comprises a resin.

5. The battery module according to claim 1, wherein: The thermally conductive resin layer does not overflow to the outside of the pad and the reinforcing material. The battery module according to claim 1 , wherein: The reinforcing material is first provided on one surface of the battery cell stack in an uncured state, and then when the battery cell stack is accommodated in the module frame, the reinforcing material is formed to be compressed and cured between the battery cell stack and the mat.

7. The battery module according to claim 1, wherein: The reinforcing material is polyurethane foam, namely PU foam.

8. The battery module according to claim 1, wherein: The reinforcing material is silicone resin.

9. The battery module according to claim 1, wherein: A plurality of the pads are provided at both ends of the one surface of the module frame, and The thermally conductive resin layer is disposed between the pads.

10. A battery pack comprising the battery module according to claim 1.

Images