Battery pack including foam pad gasket

Abstract

A battery pack is disclosed, comprising: a battery cell stack including a plurality of stacked battery cells; a battery pack body configured to house the battery cell stack; a battery pack cover added to cover the open upper surface of the battery pack body; and a foam pad disposed at the joint between the battery pack body and the battery pack cover, wherein through holes for bolt insertion are formed on the outer periphery of the battery pack cover. The battery pack can be assembled through a simple process and maintains its airtightness even after repeated disassembly and reassembly.

Description

Technical Field

[0001] This application claims the benefit of priority to Korean Patent Application No. 2024-0114197, filed on August 26, 2024, and Korean Patent Application No. 2025-0109336, filed on August 7, 2025, the disclosures of which are incorporated herein by reference in their entirety.

[0002] This disclosure relates to a battery pack including a foam pad gasket. More specifically, this disclosure relates to a battery pack including a foam pad gasket that ensures the airtightness of the battery pack without damage even after repeated assembly and disassembly. Background Technology

[0003] Lithium-ion rechargeable batteries, which charge and discharge via lithium-ion migration, offer advantages such as high energy density and high charging voltage. Therefore, lithium-ion rechargeable batteries are used not only in small battery cells in mobile devices and small electronic products, but also in medium to large battery packs serving as energy sources for electric vehicles and energy storage systems that require high power and high voltage.

[0004] Medium to large battery packs may include battery modules in which multiple battery cells are connected in series and / or in parallel and electrically connected to each other via busbars or the like. Components configured to monitor the state of the battery pack can typically be added to at least one battery module to manufacture the battery pack.

[0005] Various attempts are underway to ensure the airtightness of the battery pack during the process of combining the battery pack body with the battery pack cover, wherein the battery pack cover is configured to cover the open upper surface of the battery pack body for assembling the battery pack.

[0006] For example, a non-asbestos gasket can be disposed and attached to the top of the battery pack body, which is attached to the side surface of the battery pack cover. The battery pack cover can be positioned above the non-asbestos gasket, and the battery pack cover and battery pack body can be attached to each other. However, this requires an additional step of attaching the non-asbestos gasket to the top of the battery pack body, and the fasteners used to secure the non-asbestos gasket may loosen, potentially resulting in a loss of airtightness after the battery pack body and battery pack cover are attached together.

[0007] Alternatively, a method can be used to bond the battery pack body and battery pack cover together by adding a sealant to the joint. However, this requires the application of sealant, and the sealant may be damaged if the battery pack is disassembled. Therefore, the airtightness may be compromised when the battery pack body and battery pack cover are reassembled.

[0008] In this regard, Patent Document 1 relates to a battery case comprising a base and a cover, wherein a sealing foam pad is inserted between a compression frame corresponding to the side surface of the base and the cover to enhance the sealing force of the battery case.

[0009] Patent Document 1 only discloses that the foam pad is placed at the joint between the roll-formed frame and the cover, and fails to propose a structure that achieves the connection between the roll-formed frame and the cover when the foam pad is inserted between them. Furthermore, in Patent Document 1, during the process of joining the roll-formed frame and the cover, the foam pad may deviate from its original position, which may require precision in the assembly process.

[0010] Therefore, there is a need for a battery pack that can ensure airtightness during assembly through a simple assembly process, and also maintain airtightness during battery pack disassembly and reassembly processes.

[0011] (Existing technical documents)

[0012] (Patent Document 1) Chinese Utility Model Registration No. 219419206 (July 25, 2023) Summary of the Invention

[0013] Technical issues

[0014] This disclosure has been made in view of the above-mentioned problems, and the purpose of this disclosure is to provide a battery pack including a foam pad that can be assembled by a simple process and maintains airtightness even during the disassembly and reassembly of the battery pack.

[0015] Technical solution

[0016] To achieve the above objectives, the battery pack according to this disclosure includes: a battery cell stack comprising a plurality of stacked battery cells; a battery pack body configured to house the battery cell stack; a battery pack cover added to cover the open upper surface of the battery pack body; and a foam pad disposed at the joint between the battery pack body and the battery pack cover, wherein through holes for bolt insertion are formed on the outer periphery of the battery pack cover.

[0017] Foam pads can be attached to the first surface of the battery pack cover.

[0018] Foam pads can be attached to the first surface of the battery pack cover using adhesive.

[0019] A groove configured to accommodate a foam pad can be formed in the first surface of the battery pack cover, and the groove can be formed along the outer periphery of the battery pack cover and can be bent around the periphery of the through hole.

[0020] The battery pack cover may include a second surface that is the outer surface opposite to the first surface, and the portion of the second surface corresponding to the groove of the first surface may be formed into a flat shape.

[0021] The battery pack cover may include a second surface that is an outer surface opposite to the first surface, and the portion of the second surface corresponding to the groove of the first surface may be formed as a convex shape.

[0022] Foam pads can be formed into a continuous, uninterrupted shape.

[0023] With the battery pack cover and the battery pack body connected to each other by bolts, the foam pad can be deformed into a compressed shape.

[0024] The vertical cross-section of the groove can have a polygonal shape, a semi-circular shape, a semi-elliptical shape, an elliptical shape, or a circular, elliptical, or polygonal shape in which at least a portion is removed.

[0025] At least a portion of the foam pad can be accommodated in the groove, and the portion of the foam pad accommodated in the groove can be compressed while completely filling the internal space of the groove.

[0026] The horizontal cross-section of the groove parallel to the first and second surfaces can be formed such that the cross-sectional area of ​​the groove is maximized at the first surface, and the cross-sectional area of ​​the groove decreases as it moves further into the groove.

[0027] The horizontal cross-section of the groove, parallel to the first and second surfaces, can be formed such that the cross-sectional area of ​​at least one point inside the groove is greater than the cross-sectional area of ​​the groove formed on the first surface.

[0028] In addition, this disclosure can provide various combinations of the above-mentioned technical means.

[0029] Beneficial effects

[0030] In the battery pack according to this disclosure, a foam pad can be added during the bonding process between the battery pack body and the battery pack cover without any additional steps, thereby allowing the battery pack to be assembled with a simple process while ensuring the airtightness of the battery pack.

[0031] In addition, when the battery pack body and the battery pack cover are joined together, the deviation of the foam pad from its original position can be minimized.

[0032] In addition, it can prevent the airtightness of the battery pack from being damaged during the process of disassembling and reassembling the battery pack. Attached Figure Description

[0033] Figure 1 This is an exploded perspective view of the battery pack according to this disclosure.

[0034] Figure 2 It is shown Figure 1 A perspective view of the first surface of the battery pack cover in the battery pack.

[0035] Figure 3 This is a perspective view showing the second surface of the battery pack cover according to the first embodiment.

[0036] Figure 4 It is along Figure 3 A vertical sectional view taken by line A-A'.

[0037] Figure 5 This is a perspective view showing the second surface of the battery pack cover according to the second embodiment.

[0038] Figure 6 It is along Figure 5 The vertical section view taken by line B-B'.

[0039] Figure 7 This is a vertical cross-sectional view showing the foam pad of the battery pack cover according to an embodiment and a portion thereof.

[0040] Figure 8 This is a vertical cross-sectional view showing a portion of the foam padding of a battery pack cover and its attachment, according to another embodiment. Detailed Implementation

[0041] Preferred embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings, enabling those skilled in the art to readily implement the preferred embodiments of the present disclosure. However, in describing the operating principles of the preferred embodiments of the present disclosure, detailed descriptions of known functions and configurations incorporated herein will be omitted where such inclusion might obscure the subject matter of the disclosure.

[0042] Furthermore, throughout the accompanying drawings, the same reference numerals will be used to refer to components that perform similar functions or operations. Throughout the specification, when a component is referred to as being connected to another component, that component can be directly connected to that other component, or indirectly connected to that other component via yet another component. Additionally, unless otherwise stated, including a particular element does not mean excluding other elements, but rather means that such elements may be further included.

[0043] Furthermore, descriptions of elements by limiting or adding to them can be applied to all inventions unless otherwise specified, and do not limit any particular invention.

[0044] Furthermore, in the description of this disclosure and the claims of this application, unless otherwise stated, the singular form is intended to include the plural form.

[0045] Furthermore, in the specification and claims of this application, unless otherwise stated, "or" includes "and". Therefore, "including A or B" means three cases: including A, including B, and including both A and B.

[0046] Embodiments of this disclosure will be described in detail with reference to the accompanying drawings.

[0047] Figure 1 This is an exploded perspective view of the battery pack according to this disclosure.

[0048] Reference Figure 1 The battery pack according to this disclosure includes: a battery pack body 100 having an open upper surface, the battery pack body being configured to house a plurality of battery cells therein; a battery pack cover 200 added to cover the upper surface of the battery pack body 100; and a foam pad 300 disposed at the joint where the battery pack body 100 and the battery pack cover 200 are joined together.

[0049] At least one battery module may be housed in the battery pack body 100, wherein the battery module comprises a plurality of battery cells stacked together and electrically connected to each other via busbars or the like.

[0050] When multiple battery modules are housed in the battery pack body 100, sidewalls or frames can be provided to separate the internal space of the battery pack body, and one or more battery modules can be housed in the respective separated internal spaces of the battery pack body in a state of being connected in series and / or in parallel.

[0051] Additionally, components such as sensors configured to monitor the temperature and voltage of multiple battery cells and management units configured to prevent malfunctions may be included in the assembly of the battery pack.

[0052] The battery pack cover 200 is a component that is incorporated to cover the upper surface of the battery pack body 100, which contains individual battery cells, and bolt insertion through holes 220 are formed along the outer periphery 210 of the battery pack cover 200. Therefore, the battery pack cover 200 can be stably attached to the top of the battery pack body 100 by bolts inserted into the through holes 220.

[0053] Typically, gaskets are inserted between the battery pack body and the battery pack cover to ensure airtightness, in order to prevent harmful substances from being introduced into the battery pack and to prevent flames or high-temperature gases generated in the battery pack from spreading out of the battery pack.

[0054] This disclosure uses a foam pad that will not deform or be damaged even when the battery pack is repeatedly turned on and off.

[0055] The foam pad 300 can be manufactured to have a specific shape, be elastically deformable, and be able to block the movement of gases and liquids. The material of the foam pad 300 is not particularly limited, as long as it can perform the above functions, but may include, for example, at least one selected from the group consisting of polyurethane, polyethylene, ethylene vinyl acetate, polyvinyl chloride, silicone rubber, ethylene propylene diene monomer, and nitrile rubber.

[0056] With the battery pack cover 200 and the battery pack body 100 connected to each other by bolts, the fastening force generated by the bolts can strongly act on the foam pad 300, thereby deforming the foam pad 300 into a compressed shape.

[0057] Figure 2 It is shown Figure 1 A perspective view of the first surface of the battery pack cover in the battery pack. Figure 3 This is a perspective view showing the second surface of the battery pack cover according to the first embodiment, and Figure 4 It is along Figure 3 A vertical sectional view taken by line A-A'.

[0058] Reference Figures 2 to 4 The battery pack cover 200 includes a first surface 201 located in the direction in which the battery pack cover is joined to the battery pack body and a second surface 202 as the outer surface opposite to the first surface 201, wherein a foam pad 300 is attached to the first surface 201 of the battery pack cover 200.

[0059] A groove 230 is formed on the outer periphery 210 of the first surface 201 of the battery pack cover 200 to accommodate a foam pad 300, and an adhesive 250 can be applied to the interior of the groove 230. Therefore, the foam pad 300 can be attached to the first surface 201 of the battery pack cover 200 by the adhesive 250, and at least a portion of the foam pad 300 can be inserted into the groove 230.

[0060] Alternatively, an adhesive can be added to the outer surface of the foam pad 300 attached to the battery pack cover 200, or an adhesive tape coated on the substrate can be added, and the foam pad 300 with the adhesive or tape can be inserted into and attached to the groove 230 formed in the first surface 201.

[0061] The adhesive may be at least one selected from, for example, the group consisting of epoxy resins, polyurethane-based resins, rubber-based resins, vinyl chloride resins and silicone-based resins.

[0062] In addition, to ensure that the foam pad 300 remains stably attached even in high-temperature environments, the adhesive may contain highly heat-resistant polymers, such as polyphenylene ether, polyphenylene sulfide, polyarylsulfone, or polyimide, or inorganic materials, such as ceramics, phosphorus, boron, or silica.

[0063] In a specific embodiment, since a through hole 220 for bolt insertion is formed on the outer periphery 210 of the battery pack cover 200, the foam pad 300 needs to be configured not to block the through hole 220. Therefore, a groove 230 configured to receive the foam pad 300 is formed along the outer periphery 210 of the battery pack cover 200 and is formed in a curved shape around the through hole 220.

[0064] On the other hand, the foam pad 300 is inserted between the mating surfaces of the battery pack body 100 and the battery pack cover 200, and serves as a device configured to ensure the airtightness of the battery pack. The foam pad is formed in a continuous shape along the outer periphery of the battery pack body 100 and the battery pack cover 200, thereby completely blocking the inflow and outflow of gas and liquid.

[0065] Reference Figure 3 The battery pack cover 200 includes a second surface 202, which is the outer surface opposite to the first surface 201, wherein the outer periphery 210 of the second surface 202 corresponding to the groove 230 in the first surface 201 is formed into a flat shape.

[0066] In this case, the foam pad 300 can be stably located in the groove 230 while being bonded by the adhesive 250, and the outer periphery 210 of the second surface 202 of the battery pack cover 200 can be a flat surface without steps.

[0067] Figure 5 This is a perspective view showing the second surface of the battery pack cover according to the second embodiment, and Figure 6 It is along Figure 5 The vertical section view taken by line B-B'.

[0068] Reference Figure 5 and Figure 6 The difference between the battery pack cover according to the second embodiment and the battery pack cover according to the first embodiment is that a protrusion 240 is formed on the outer periphery 210 of the battery pack cover 200.

[0069] Specifically, a groove 230 configured to accommodate a foam pad 300 can be formed on the outer periphery 210 of the first surface 201 of the battery pack cover 200, and an adhesive 250 can be added to the groove 230, wherein a portion of the foam pad 300 can be bonded to the interior of the groove 230 by the adhesive 250 while being accommodated in the groove 230.

[0070] In the battery pack cover 200 according to the second embodiment, a groove 230 is formed in the first surface 201, and a protrusion 240 is formed on the second surface 202 and protrudes convexly to correspond to the groove 230. Therefore, the thickness of the battery pack cover 200 at the portion where the groove 230 is formed does not need to be reduced. In addition, compared with the battery pack cover according to the first embodiment, the depth of the groove 230 can be further increased, thereby allowing the foam pad 300 to be more stably accommodated in the groove and fixed to the groove.

[0071] The description of the battery pack according to the first embodiment can be applied in the same way to the battery pack cover according to the second embodiment.

[0072] Figure 7 This is a vertical cross-sectional view showing the foam pad of the battery pack cover according to an embodiment and a portion thereof.

[0073] Reference Figure 7 The foam pad 300 shown in (a) and (b) is attached to the groove of the battery pack cover 200 by adhesive 250. The foam pad 300 shown in (a) has a diamond-shaped vertical cross section, and the foam pad 300 shown in (b) has a rectangular vertical cross section.

[0074] In (a), the vertical cross-sectional shape of the groove 230 formed in the battery pack cover 200 is triangular, and in (b), the vertical cross-sectional shape of the groove 230 formed in the battery pack cover 200 is quadrilateral. Additionally, Figure 4 and Figure 6 The vertical cross-section of the groove 230 shown is semi-circular or semi-elliptical. Furthermore, as... Figure 8 As shown, the vertical cross-section of the groove 230 can have an elliptical shape, a circular or elliptical shape with at least a portion removed, or a polygonal shape with at least a portion removed.

[0075] At least a portion of the foam pad 300 bonded to the battery pack cover 200 is accommodated in the groove 230, and to increase the bonding force between the foam pad 300 and the groove 230, a portion of the foam pad 300 accommodated in the groove 230 may be formed into a shape corresponding to the shape of the groove 230. Alternatively, the size of the foam pad 300 may be larger than the size of the groove 230, and the foam pad 300 may be compressed and deformed while completely filling the internal space of the groove 230 after being inserted into it.

[0076] Furthermore, despite Figure 7 The second surface 202 of the battery pack cover 200 shown is convex, but Figure 7 The groove 230 and foam pad 300 shown can also be applied to Figure 4The battery pack cover 200 shown has a flat second surface 202.

[0077] exist Figure 4 , Figure 6 and Figure 7 In the battery pack cover 200 shown, when the first surface 201 and the second surface 202 are parallel to each other, the cross section of the groove 230 parallel to the first surface 201 and the second surface 202 can be considered as the horizontal cross section of the groove. For example... Figure 7 As shown in (b), the cross-sectional area of ​​the groove (which is the area of ​​the horizontal cross-section of the groove) can be uniform, regardless of the position of the battery pack cover 200 in the thickness direction, or as... Figure 4 , Figure 6 and Figure 7 As shown in (a), the cross-sectional area of ​​the groove can vary depending on the position of the battery pack cover 200 in the thickness direction. Figure 4 , Figure 6 and Figure 7 In the groove 230 shown, the cross-sectional area of ​​the groove 230 is largest at the first surface 201, and the cross-sectional area of ​​the groove can be smaller towards the inside of the groove, or the cross-sectional area of ​​the groove can be uniform.

[0078] Figure 8 This is a vertical cross-sectional view showing a portion of the foam padding of a battery pack cover and its attachment, according to another embodiment.

[0079] Reference Figure 8 When the first surface 201 and the second surface 202 of the battery pack cover 200 are parallel to each other, the horizontal cross section of the groove 230 parallel to the first surface 201 and the second surface 202 is formed such that the cross-sectional area of ​​at least one point inside the groove 230 is greater than the cross-sectional area of ​​the groove 230 formed on the first surface 201.

[0080] In other words, due to Figure 8 The groove 230 of the battery pack cover 200 shown is formed such that the cross-sectional area of ​​the groove 230 at the groove entrance 231 through which the foam pad 300 is inserted is smaller than the maximum cross-sectional area inside the groove 230. Therefore, the foam pad 300 inserted into the groove 230 can be anchored and firmly fixed at the groove entrance 231 in an elastic deformation state.

[0081] although Figure 8 The adhesive 250 is shown being applied to the interior of the groove 230, but the adhesive 250 may not be applied to the interior of the groove 230. Additionally, although... Figure 8 The second surface is shown to be flat, but even when the protrusions are formed convexly on the second surface 202, as... Figure 6 and Figure 7 As shown, it can also be used Figure 8 The shape of the groove 230 shown.

[0082] In this disclosure, as described above, the foam pad 300 is stably bonded to the groove 230 of the battery pack cover 200, so that when the battery pack body 100 and the battery pack cover 200 are joined together by bolts, the foam pad 300 can be stably fixed to the groove 230 without escaping from the groove. Therefore, the battery pack can be assembled easily and quickly.

[0083] Those skilled in the art to which this disclosure pertains will understand that various applications and modifications are possible within the scope of this disclosure based on the above description.

[0084] (Explanation of reference numerals in the attached image)

[0085] 100: Main body of the battery pack

[0086] 200: Battery pack cover

[0087] 201: First Surface

[0088] 202: Second Surface

[0089] 210: Outer perimeter

[0090] 220: Through hole

[0091] 230: Groove

[0092] 231: Groove entrance

[0093] 240: Protrusion

[0094] 250: Adhesive

[0095] 300: Foam pad / gasket

Claims

1. A battery pack, comprising: A battery cell stack, wherein the battery cell stack comprises multiple stacked battery cells; A battery pack body configured to house the stack of battery cells; A battery pack cover is added to cover the open upper surface of the battery pack body; as well as A foam pad is disposed at the joint between the battery pack body and the battery pack cover. The battery pack cover has through holes formed on its outer periphery for bolt insertion.

2. The battery pack according to claim 1, wherein, The foam pad is attached to the first surface of the battery pack cover.

3. The battery pack according to claim 2, wherein, The foam pad is attached to the first surface of the battery pack cover by an adhesive.

4. The battery pack according to claim 2, wherein, A groove configured to receive the foam pad is formed on the first surface of the battery pack cover, and The groove is formed along the outer periphery of the battery pack cover and curves around the through hole.

5. The battery pack according to claim 4, wherein, The battery pack cover includes a second surface that is the outer surface opposite to the first surface, and The portion of the second surface corresponding to the groove on the first surface is formed into a flat shape.

6. The battery pack according to claim 4, wherein, The battery pack cover includes a second surface that is the outer surface opposite to the first surface, and The portion of the second surface corresponding to the groove on the first surface is formed as a convex shape.

7. The battery pack according to claim 1, wherein, The foam pad is formed in a continuous, uninterrupted shape.

8. The battery pack according to claim 1, wherein, With the battery pack cover and the battery pack body connected to each other by bolts, the foam pad is deformed into a compressed shape.

9. The battery pack according to claim 5, wherein, The vertical cross-section of the groove has a polygonal shape, a semi-circular shape, a semi-elliptical shape, an elliptical shape, or a circular, elliptical, or polygonal shape with at least a portion removed.

10. The battery pack according to claim 9, wherein, At least a portion of the foam pad is accommodated in the groove, and The portion of the foam pad accommodated in the groove is compressed while completely filling the internal space of the groove.

11. The battery pack according to claim 10, wherein, The horizontal cross-section of the groove, parallel to the first and second surfaces, is formed such that the cross-sectional area of ​​the groove is maximized at the first surface, and the cross-sectional area of ​​the groove decreases as it moves further into the interior of the groove.

12. The battery pack according to claim 10, wherein, The horizontal cross-section of the groove, parallel to the first and second surfaces, is formed such that the cross-sectional area of ​​at least one point inside the groove is greater than the cross-sectional area of ​​the groove formed on the first surface.

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