Method for manufacturing battery module

Abstract

The present disclosure provides a method of manufacturing a battery module, the battery module including: a frame including a lower plate having a first hole; a battery cell accommodated in the frame; and a resin coated and cured between the battery cells and the lower plate, the method for manufacturing the battery module comprising: a step of attaching a resin tape; a step of injecting an uncured resin; and removing the resin tape. The resin tape includes a reinforcing portion whose toughness in the first direction is stronger than other portions of the resin tape.

Description

Technical Field

[0001] The priority interest of this application is claimed in Korean Patent Application No. 10-2024-0044194, filed on April 1, 2024, and all the contents disclosed in the patent application documents are included as part of this specification.

[0002] This disclosure relates to a resin strip structure capable of removing excess resin after injection of uncured resin to prevent resin strip breakage, and a method for manufacturing a battery module. Background Technology

[0003] Secondary batteries, offered by product groups, are characterized by ease of use and high energy density, and are widely used not only in portable devices but also in electric or hybrid vehicles powered by electric sources, as well as in energy storage devices. These secondary batteries are gaining attention as a new energy source for improving eco-friendliness and energy efficiency, not only because of their key advantage of significantly reducing fossil fuel use, but also because they do not produce any byproducts from energy consumption.

[0004] While small mobile devices use one, two, or three battery cells per device, medium to large devices, such as vehicles, require high output and large capacity. Therefore, medium to large-sized battery modules with multiple battery cells connected together are used.

[0005] Figure 1 and Figure 2 The structure of the battery module is shown. (Refer to...) Figure 1 and Figure 2 The battery module M is manufactured by placing stacked battery cells 2 within a metal frame 1. For example... Figure 2 As shown, the frame 1 can form a box-shaped housing together with other plates covering the upper end, front end and rear end of the battery cell 2.

[0006] Resin 4 is disposed between the lower plate of frame 1 and the lower surface of battery cell 2. Resin 4 is applied to the lower plate, and then battery cell 2 is placed on it. The resin 4 is cured to fix battery cell 2 to frame 1 by adhesive. Resin 4 is made of a material with high thermal conductivity and can conduct heat generated in battery cell 2 during charging and discharging to frame 1 for heat dissipation.

[0007] Figure 3 It shows Figure 1 The lower surface of the battery module frame. (Refer to...) Figure 3 Multiple first holes 10 for injecting resin 4 can be provided in the frame 1. A portion of the multiple first holes 10 can be configured for checking whether the space between the battery cell 2 and the frame 1 is completely filled with resin 4.

[0008] Figure 4 It shows the one with the resin tape attached. Figure 3 The framework, and Figure 5 A cross-section of the battery module after resin injection is shown. (Refer to...) Figure 4 and Figure 5 After resin 4 is injected through the first hole 10, resin tape 3 can be used to remove excess resin that has overflowed. Resin tape 3 has a second hole 300 corresponding to the first hole 10 to receive excess resin that has overflowed through the first hole 10, and the excess resin can also be removed as resin tape 3 is removed.

[0009] Figure 6 It shows Figure 5 The resin strip was torn during its removal. (See reference) Figure 6 The resin strip 3 may tear during removal. This is especially likely to happen when the resin 4 has cured and formed sharp edges. In this case, it is difficult to remove the excess resin and the resin strip 3 sandwiched between the excess resin and the frame 1. Summary of the Invention

[0010] Technical issues

[0011] To address the aforementioned problems of the prior art, the object of this disclosure is to provide a resin tape structure that is not easily torn. Specifically, one object of this disclosure is to provide an economical resin tape structure that will not be torn by the sharp edges of excess cured resin.

[0012] Another object of this disclosure is to provide a method for manufacturing a battery module that can smoothly perform resin injection and excess resin removal.

[0013] The technical problem to be solved by this disclosure is not limited to the above-described objectives, and other objectives and advantages of this disclosure not described herein may be understood through the following description and will become clearer through examples of this disclosure. Furthermore, it will be apparent that the objectives and advantages of this disclosure may be implemented by the means defined in the claims and combinations thereof.

[0014] Technical solution

[0015] To address the aforementioned problems, this disclosure provides a battery manufacturing method for manufacturing a battery module. The battery module includes: a frame having a lower plate with a first hole; a battery cell housed within the frame; and resin coated and cured between the battery cell and the lower plate. The battery manufacturing method sequentially includes: a resin tape attachment step, attaching a resin tape having a second hole located at a position corresponding to the first hole to the surface of the lower plate of the frame housing the battery cell; a resin injection step, injecting uncured resin through the first and second holes while the surface of the lower plate is facing upwards; and a resin tape removal step, removing the resin tape from the lower plate. The resin tape includes a first reinforcing portion extending along a first direction, and the first reinforcing portion exhibits greater toughness along the first direction than other portions of the resin tape.

[0016] A plurality of first holes and a plurality of second holes arranged in a first direction can be provided. Here, since the extending direction of the first reinforcing part is parallel to the arrangement direction of the first holes and the second holes, the first reinforcing part can be spaced apart from the first holes and the second holes by a predetermined distance or less.

[0017] In the resin tape removal step, the resin tape can be unattached starting from one end in the first direction and ending at the other end in the first direction. That is, the resin tape can be unattached along the first direction. Here, because the resin tape includes a first reinforcing portion with high toughness along the first direction, the resin tape is not easily torn during the unattachment process.

[0018] Multiple first reinforcing parts can be provided, arranged along the second direction.

[0019] According to aspects of this disclosure, a pair of first reinforcing portions may be provided on both sides of the second hole in a second direction.

[0020] In this case, during the resin injection step, resin can be injected until it overflows from the second hole and covers at least a portion of the pair of first reinforcing parts.

[0021] Therefore, a force can be applied to the first reinforcing section during the removal of the resin strip to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip.

[0022] According to a first variation of this disclosure, the first reinforcing portion may be disposed on one side of the second hole along the second direction. In this case, it is more economical than providing a pair of first reinforcing portions.

[0023] In this case, the resin injection step can be performed with the surface of the lower plate tilted to one side in the second direction. Here, resin can be injected until it overflows from the second hole and covers at least a portion of the first reinforcing part.

[0024] Therefore, a force can be applied to the first reinforcing section during the removal of the resin strip to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip.

[0025] According to a second variation of this disclosure, the resin tape may further include a second reinforcing portion extending in a second direction, the second reinforcing portion having greater toughness in the second direction than the other portions of the resin tape in the second direction.

[0026] The resin tape may include a first tape having an adhesive surface and a non-adhesive surface, and a non-adhesive surface attached to the first tape, and the resin tape is more resilient than the first tape to form a second tape with a first reinforcement and a second reinforcement.

[0027] In the resin tape removal step, the resin tape can be unattached starting from one end in the second direction and ending at the other end in the second direction. That is, the resin tape can be unattached along the second direction. Here, because the resin tape includes a second reinforcing portion with high toughness along the second direction, the resin tape is not easily torn during the unattachment process.

[0028] Multiple second reinforcing parts can be provided, arranged along the first direction.

[0029] For example, a pair of second reinforcing parts can be provided on both sides of the second hole in the first direction.

[0030] In this case, during the resin injection step, resin can be injected until it overflows from the second hole and covers at least a portion of the pair of second reinforcing parts.

[0031] Therefore, force can be applied to the second reinforcement during the removal of the resin strip to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip.

[0032] Alternatively, the second reinforcement can be provided on one side of the second hole in the first direction. In this case, it is more economical than providing a pair of second reinforcements.

[0033] In this case, the resin injection step can be performed with the surface of the lower plate tilted to one side in the first direction, and the resin can be injected until the resin overflows from the second hole and covers at least a portion of the second reinforcing part.

[0034] Therefore, force can be applied to the second reinforcement during the removal of the resin strip to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip.

[0035] Beneficial effects

[0036] This disclosure provides an economical resin tape structure that is not easily torn by adding a tough reinforcing section.

[0037] This disclosure may also provide a method for manufacturing a battery module that can effectively remove excess resin.

[0038] Furthermore, this disclosure may have various other effects, which will be described in various aspects, or descriptions of effects that can be readily inferred by those skilled in the art will be omitted. Attached Figure Description

[0039] Figure 1 and Figure 2 The structure of the battery module is shown.

[0040] Figure 3 It shows Figure 1 The lower surface of the battery module frame.

[0041] Figure 4 It shows the one with the resin tape attached. Figure 3 The framework.

[0042] Figure 5 A cross-section of the battery module after resin injection is shown.

[0043] Figure 6 It shows Figure 5 The resin strip was torn during its removal.

[0044] Figure 7 and Figure 8 A battery module according to aspects of this disclosure is shown.

[0045] Figure 9 The lower surface of the framework according to aspects of this disclosure is shown.

[0046] Figure 10 A method for manufacturing a battery module according to aspects of this disclosure is shown.

[0047] Figure 11 A frame with a resin tape attached according to aspects of this disclosure is shown.

[0048] Figure 12 It shows Figure 11 The main part of the frame has a resin strip.

[0049] Figure 13 The resin injection process is shown. Figure 11 A frame with resin tape.

[0050] Figure 14 It shows Figure 13 The main part of the framework.

[0051] Figure 15 The removed resin strip is shown according to aspects of this disclosure.

[0052] Figure 16 A battery module and resin strip according to a first variant of this disclosure are shown.

[0053] Figure 17 The resin injection process is shown. Figure 16 The battery module.

[0054] Figure 18 A battery module and resin strip according to a second variation of this disclosure are shown.

[0055] [Explanation of reference numerals in the attached figures]

[0056] 1: Framework

[0057] 10: First hole

[0058] 2: Battery cell

[0059] 3: Resin tape

[0060] 30: First Belt

[0061] 300: Second hole

[0062] 31: First Reinforced Section (Second Belt)

[0063] 32: Second Reinforced Section (Second Belt)

[0064] 4: Resin

[0065] M: Battery module Detailed Implementation

[0066] The above-described objects, features, and advantages will now be described in detail with reference to the accompanying drawings, enabling those skilled in the art to realize the technical concept of this disclosure. In describing this disclosure, detailed descriptions of prior art related to this disclosure will be omitted where it is determined that such detailed descriptions unnecessarily obscure the spirit of the disclosure. Hereinafter, preferred aspects according to this disclosure will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used to indicate the same or similar components.

[0067] Although terms such as "first" and "second" are used to describe various elements, these elements are certainly not limited by these terms. These terms are only used to distinguish one element from another, and unless otherwise specified, the first element may also be the second element.

[0068] Throughout this specification, unless otherwise stated, each element may be singular or plural.

[0069] In the following text, “arranging an element at the top (or bottom) of an element” or “arranging an element at the top (or bottom) of an element” means not only “arranging an element to contact the upper (or lower) surface”, but also “arranging an element on the upper (or lower) surface and inserting another element therebetween”.

[0070] Additionally, when an element is described as being “connected to” another element, “combined” with another element, or “in contact” with another element, it should be understood that the element may be “directly connected to” another element, “directly combined” with another element, or “directly in contact” with another element, or the element may be “connected to” another element, “combined” with another element, or “in contact” with another element, or another element may be inserted therein.

[0071] Unless the context clearly specifies otherwise, the singular forms used herein include the plural forms. Terms such as “consisting of” or “comprising” used herein should not be construed as including all elements or steps described in the specification, and should be construed as excluding some elements or steps, or including additional elements or steps.

[0072] Throughout this specification, unless otherwise specified, “A and / or B” means A, B, or A and B, and unless otherwise specified, “C to D” means from equal to or higher than C to equal to or lower than D.

[0073] For convenience, throughout this specification, the first direction may be interpreted as the width direction or the direction of the shorter side, and the second direction may be interpreted as the length direction or the direction of the longer side. However, this is only for ease of description and understanding, and strictly speaking, the first and second directions should be interpreted as a horizontal direction and another horizontal direction intersecting with it.

[0074] Preferred aspects of this disclosure will be described in detail below with reference to the accompanying drawings.

[0075] Figure 7 and Figure 8 A battery module according to aspects of this disclosure is shown. (Refer to...) Figure 7 and Figure 8 According to aspects of this disclosure, the battery module M may include a battery cell 2, a frame 1 for housing the battery cell 2, and a resin 4 disposed between the frame 1 and the battery cell 2.

[0076] The battery cell 2 can be a pouch cell with multiple cells stacked together, but is not limited to this, and the battery cell 2 can be any type of battery cell, as long as the battery cell has a predetermined lower surface that can be attached to the resin 4.

[0077] Frame 1 has an open upper end, an open front end, and / or an open rear end, and can form a housing together with other plate components that house the battery cell 2. However, there are no specific limitations on the shape of frame 1.

[0078] Frame 1 may contain metallic materials.

[0079] The resin 4 can be injected between the frame 1 and the battery cell 2 and then cured, thereby fixing the battery cell 2 to the frame 1 by adhesive. Here, the resin 4 may include a material with high thermal conductivity, so that the heat generated from the battery cell 2 is conducted to the frame 1 for heat dissipation. That is, the resin 4 can connect the battery cell 2 to the frame 1 by mechanical and thermal means.

[0080] Figure 9 The lower surface of the framework according to aspects of this disclosure is shown. (Refer to...) Figure 9 The frame 1 may include a first hole 10 through which resin 4 can be injected. According to an aspect of this disclosure, after the battery cell 2 is housed in the frame 1, the battery module M can be manufactured by filling and curing the resin 4 between the frame 1 and the battery cell 2 through the first hole 10 with the lower surface of the frame 1 facing upward.

[0081] The method for manufacturing the battery module M according to aspects of this disclosure will be described in detail below.

[0082] Figure 10 A method for manufacturing a battery module according to aspects of this disclosure is shown. (Refer to...) Figure 10 The method for manufacturing a battery module according to aspects of this disclosure includes, in sequence: step S1, placing a frame 1 containing a battery cell 2 with its lower surface facing upward; resin tape attachment step S2, attaching a resin tape 3 having a second hole located at a position corresponding to the position of the first hole 10 to the surface of the lower plate of the frame 1; resin injection step S3, injecting uncured resin 4 through the first hole 10 and the second hole; and resin tape removal step S4, removing the resin tape 3 from the lower plate.

[0083] According to an aspect of this disclosure, after the injection of resin 4 is completed, the resin strip 3 is removed to remove excess resin injected through the first hole 10 and the second hole and overflowing from the first hole 10 and the second hole.

[0084] Figure 11 A frame with a resin tape attached according to aspects of this disclosure is shown, and Figure 12 It shows Figure 11 The main part of the frame has a resin strip. (Refer to...) Figure 11 and Figure 12 The resin tape 3 may have a second hole 300 corresponding to the first hole 10.

[0085] The resin tape 3 may include a first reinforcing portion 31, which extends along a first direction and has greater toughness along the first direction than other portions of the resin tape 3 along the first direction. For example, the resin tape 3 may include: a first tape 30 having an adhesive surface and a non-adhesive surface; and a second tape 31 attached to the non-adhesive surface of the first tape 30, wherein the second tape 31 has greater toughness than the first tape 30 to form the first reinforcing portion 31.

[0086] A plurality of first holes 10 and a plurality of second holes 300 can be provided arranged in a first direction. Here, since the extending direction of the first reinforcing part 31 is parallel to the arrangement direction of the first holes 10 and the second holes 300, the first reinforcing part 31 can be spaced apart from the first holes 10 and the second holes 300 by a predetermined distance or less.

[0087] Multiple first reinforcing parts 31 arranged along the second direction can be provided.

[0088] According to this disclosure, a pair of first reinforcing parts 31 may be provided, respectively arranged on both sides of the second hole 300 in a second direction.

[0089] Figure 13 The resin injection process is shown. Figure 11 The frame has a resin strip, and Figure 14 It shows Figure 13 The main part of the framework. (Refer to...) Figure 13 and Figure 14 In the resin injection step S3 according to aspects of this disclosure, resin 4 may be injected until resin 4 overflows from the second hole 300 and covers at least a portion of the pair of first reinforcing parts 31.

[0090] Figure 15 The removed resin strip according to aspects of this disclosure is shown. (Refer to...) Figure 15 In the resin tape removal step S4, the resin tape 3 can be unattached from one end in the first direction and to the other end in the first direction. That is, the resin tape 3 can be unattached along the first direction. Here, since the resin tape 3 includes a first reinforcing portion 31 with high toughness along the first direction, the resin tape 3 is not easily torn during the unattachment process.

[0091] According to aspects of this disclosure, when resin 4 overflows and covers at least a portion of the first reinforcing portion 31, force can be applied to the first reinforcing portion 31 during the removal of the resin strip 3 to lift the overflowing resin. Therefore, excess resin can be easily removed, and tearing of the resin strip 3 can be prevented.

[0092] Figure 16 A battery module and resin strip according to a first variant of this disclosure are shown. (See reference...) Figure 16In a variant, the first reinforcing part 31 may be provided on one side of the second hole 300 in the second direction. In this case, it is more economical than providing a pair of first reinforcing parts 31.

[0093] Figure 17 The resin injection process is shown. Figure 16 The battery module. (Refer to...) Figure 17 The resin injection step S3 according to the first variant can be performed with the surface of the lower plate tilted to one side in the second direction. Here, resin 4 can be injected until resin 4 overflows from the second hole 300 and covers at least a portion of the first reinforcing part 31.

[0094] Therefore, a force can be applied to the first reinforcing portion 31 during the removal of the resin strip 3 to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip 3.

[0095] Figure 18 A battery module and resin strip according to a second variation of this disclosure are shown. (See reference...) Figure 18 According to the second variant, the resin strip 3 may further include a second reinforcing portion 32, which extends along a second direction and has greater toughness along the second direction than the other portions of the resin strip 3 along the second direction.

[0096] The resin tape 3 may include: a first tape 30 having an adhesive surface and a non-adhesive surface; and a second tape 32 attached to the non-adhesive surface of the first tape 30, wherein the second tape 32 is more resilient than the first tape 30 to form a first reinforcing portion 31 and a second reinforcing portion 32.

[0097] In the resin tape removal step S4, the resin tape 3 can be unattached from one end in the second direction and to the other end in the second direction. That is, the resin tape 3 can be unattached along the second direction. Here, since the resin tape 3 includes a second reinforcing portion 32 with high toughness along the second direction, the resin tape 3 is not easily torn during the unattachment process.

[0098] Multiple second reinforcing parts 32 arranged along the first direction can be provided.

[0099] For example, a pair of second reinforcing parts 32 may be provided on both sides of the second hole 300 in the first direction.

[0100] In this case, in the resin injection step S3, resin 4 can be injected until resin 4 overflows from the second hole 300 and covers at least a portion of the pair of second reinforcing parts 32.

[0101] Therefore, a force can be applied to the second reinforcing portion 32 during the removal of the resin strip 3 to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip 3.

[0102] Alternatively, the second reinforcing part 32 can be provided on one side of the second hole 300 in the first direction. In this case, it is more economical than providing a pair of second reinforcing parts 32.

[0103] In this case, the resin injection step S3 can be performed with the surface of the lower plate tilted to one side in the first direction. Here, resin 4 can be injected until resin 4 overflows from the second hole 300 and covers at least a portion of the second reinforcing part 32.

[0104] Therefore, a force can be applied to the second reinforcing portion 32 during the removal of the resin strip 3 to lift the overflowing resin. This allows for easy removal of excess resin and prevents tearing of the resin strip 3.

[0105] It should be understood that the aspects described are illustrative in all respects and not restrictive, and the scope of this disclosure will be indicated by the appended claims rather than the specific embodiments described. The meaning and scope of the claims described below, as well as all changes and modifications derived from equivalent concepts, should be interpreted as being included within the scope of this disclosure.

[0106] Although this disclosure has been described with reference to exemplary accompanying drawings, it will be understood that this disclosure is not limited to the aspects and drawings disclosed herein, and those skilled in the art will understand that various modifications are possible without departing from the scope and concept of this disclosure. Furthermore, although the operational effects of configurations according to this disclosure are not explicitly described in the description of aspects of this disclosure, it should be understood that predictable effects will also be identified depending on the configuration.

Claims

1. A method for manufacturing a battery module, the battery module comprising: A frame, the frame including a lower plate having a first hole; A battery cell, wherein the battery cell is housed in the frame; The battery manufacturing method includes, in sequence: a resin coated and cured between the battery cell and the lower plate; and a resin applied and cured between the battery cell and the lower plate. The tape attachment step involves attaching a resin tape having a second hole located at a position corresponding to the first hole to the surface of the lower plate of the frame that houses the battery cell. In the resin injection step, with the lower plate surface facing upwards, uncured resin is injected through the first and second holes; and The tape removal step involves removing the resin tape from the lower plate. The resin tape includes a first reinforcing portion, which extends along a first direction and The first reinforcing part has greater toughness along the first direction than the other parts of the resin strip.

2. The battery manufacturing method according to claim 1, wherein, The first hole and the second hole are configured as a plurality of first holes and a plurality of second holes arranged along a first direction.

3. The battery manufacturing method according to claim 1, wherein, The resin tape includes a first tape having an adhesive surface and a non-adhesive surface, and a second tape attached to the non-adhesive surface of the first tape to form the first reinforcement having greater toughness than the first tape.

4. The battery manufacturing method according to claim 1, wherein, In the tape removal step, the resin tape is unattached starting from one end of the resin tape in a first direction and ending at the other end of the resin tape in the first direction.

5. The battery manufacturing method according to claim 1, wherein, The first reinforcing part is configured as a plurality of first reinforcing parts arranged along the second direction.

6. The battery manufacturing method according to claim 5, wherein, The first reinforcing part is configured as a pair of first reinforcing parts placed on both sides of the second hole in a second direction.

7. The battery manufacturing method according to claim 6, wherein, In the resin injection step, the resin is injected until it overflows from the second hole and covers at least a portion of the pair of first reinforcements.

8. The battery manufacturing method according to claim 1, wherein, The first reinforcing part is disposed on one side of the second hole in the second direction.

9. The battery manufacturing method according to claim 8, wherein, The resin injection step is performed while the surface of the lower plate is tilted to one side in the second direction, and In the resin injection step, the resin is injected until it overflows from the second hole and covers at least a portion of the first reinforcing portion.

10. The battery manufacturing method according to claim 1, wherein, The resin tape further includes a second reinforcing portion extending in a second direction, the second reinforcing portion having greater toughness in the second direction than the other portions of the resin tape in the second direction.

11. The battery manufacturing method according to claim 10, wherein, The resin tape includes a first tape having an adhesive surface and a non-adhesive surface, and a second tape attached to the non-adhesive surface of the first tape to form the first reinforcement and the second reinforcement and having greater toughness than the first tape.

12. The battery manufacturing method according to claim 10, wherein, In the tape removal step, the resin tape is unattached starting from one end of the resin tape in the second direction and ending at the other end of the resin tape in the second direction.

13. The battery manufacturing method according to claim 10, wherein, The second reinforcing part is configured as a plurality of second reinforcing parts arranged along the first direction.

14. The battery manufacturing method according to claim 13, wherein, The second reinforcing part is configured as a pair of second reinforcing parts placed on both sides of the second hole in a first direction.

15. The battery manufacturing method according to claim 14, wherein, In the resin injection step, the resin is injected until it overflows from the second hole and covers at least a portion of the pair of second reinforcements.

16. The battery manufacturing method according to claim 10, wherein, The second reinforcing part is disposed on one side of the second hole in the first direction.

17. The battery manufacturing method according to claim 16, wherein, The resin injection step is performed with the surface of the lower plate tilted to one side in the first direction, and In the resin injection step, the resin is injected until it overflows from the second hole and covers at least a portion of the second reinforcing portion.

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