Battery pack and vehicle comprising the same

Abstract

A battery pack can be provided, including: a cell array including a plurality of battery cells; a battery pack housing assembly in which a plurality of battery pack housings configured to accommodate at least one cell array are arranged; and an exhaust valve configured to discharge exhaust gas generated from the battery cells to the outside, wherein the cell array is configured to be inserted into the battery pack housing in a first direction, and the battery pack housing is configured to be connected in a second direction perpendicular to the first direction.

Description

Technical Field

[0001] This disclosure relates to a battery pack and a vehicle including the battery pack.

[0002] This application is based on and claims priority to Korean Patent Application No. 10-2024-0116709, filed with the Korean Intellectual Property Office on August 29, 2024, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0003] Secondary batteries, which are highly adaptable based on their product group and electrical characteristics (such as high energy density), are typically used not only in portable devices but also in electric vehicles (EVs) or hybrid electric vehicles (HEVs) powered by electric power sources.

[0004] These secondary batteries have attracted attention as a new energy source to improve eco-friendliness and energy efficiency because they not only have the major advantage of significantly reducing the use of fossil fuels, but also do not produce byproducts from the use of energy.

[0005] Currently widely used rechargeable batteries include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, and nickel-zinc batteries. When a higher output voltage is required, multiple battery cells can be connected in series to form a battery module or battery pack. Additionally, to increase charging and discharging capacity, multiple battery cells can be connected in parallel to form a battery module or battery pack. Therefore, the number of battery cells included in a battery module or battery pack can be set differently depending on the required output voltage or charging and discharging capacity.

[0006] When multiple battery cells are connected in series / parallel to form a battery pack, a battery module comprising at least one battery cell is typically formed first. Then, other components are added to this at least one battery module to form a battery pack or battery rack. In this case, the battery cells are packaged into modules, and the battery modules are packaged into battery packs. Ultimately, the battery pack is installed in a vehicle, but only the battery cells are used for power supply. This over-packaging not only requires the design and manufacture of additional components but also occupies additional space, which could reduce the space occupied by the battery cells. Alternatively, battery packs in cell-to-pack form are also manufactured, where multiple battery cells are directly housed in the battery pack casing, etc., without being modularized.

[0007] Recently, with the increasing capacity of electric vehicle batteries, there is a need to develop battery packs that can maximize space utilization, minimize the number of components used in the battery pack, and simplify the assembly process in order to increase energy density while maintaining vehicle space. Summary of the Invention

[0008] Technical issues

[0009] Therefore, this disclosure relates to providing a cell-to-chassis battery pack that integrates the battery pack and the vehicle chassis and is configured to mount the cell array directly on the vehicle chassis.

[0010] In addition, this disclosure relates to providing a battery pack with enhanced stability by discharging exhaust gases generated by thermal events in the downward direction of the battery pack.

[0011] Additionally, this disclosure relates to providing a battery pack that simplifies assembly and disassembly, and can be easily scaled up or down to match the size of a vehicle by simplifying the structure of the battery pack housing and modularizing the housing for ease of manufacture.

[0012] Additionally, this disclosure relates to a battery pack that accommodates a cell array within a battery pack housing via a sliding movement method, so as to replace a defective cell array with another cell array when a defective cell array is accommodated.

[0013] This disclosure also relates to providing a vehicle that includes such a battery pack.

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

[0015] Technical solution

[0016] To address the aforementioned problems, this disclosure provides a battery pack comprising: a cell array including a plurality of battery cells; a battery pack housing assembly formed by arranging a plurality of battery pack housings configured to accommodate at least one of the cell arrays; and an exhaust valve configured to discharge exhaust gases generated from the battery cells to the outside, wherein the cell array is configured to be inserted into the battery pack housing in a first direction, and the battery pack housing is configured to be connected in a second direction perpendicular to the first direction.

[0017] The vent valve can be configured as at least one vent hole formed through a surface of the battery pack housing.

[0018] The vent valve can be configured to pass through the lower plate of the battery pack housing.

[0019] The exhaust valves can be configured to be multiple, and the multiple exhaust valves can be configured to be spaced apart from each other in the first direction.

[0020] When a thermal event occurs in the battery cell, the vent valve can guide the exhaust gas downwards.

[0021] The battery pack housing may have a rectangular tubular shape, the rectangular tubular shape having an opening formed on a front or rear surface facing the first direction.

[0022] The lower plate of the battery pack housing can be configured to form a step.

[0023] The lower plate can be divided into a downwardly protruding edge portion, a center portion positioned above the edge portion, and a middle portion positioned between the edge portion and the center portion and positioned above the center portion.

[0024] The exhaust valve can be configured to pass through the center of the lower plate.

[0025] The cell array may also include a module cover configured to support the battery cells.

[0026] The battery cell may include electrode leads that protrude downward from the lower surface of the battery cell, and the electrode leads may not be covered by the module cover.

[0027] The electrode leads and the exhaust valve can be arranged adjacent to each other.

[0028] When a thermal event occurs in the battery cell, the exhaust gas can be discharged downwards and is configured to be discharged to the outside of the battery pack through the exhaust valve.

[0029] The battery pack housing can be configured to be formed by at least one of the processes of extrusion, forging, pressing and casting.

[0030] The battery pack housings that constitute the battery pack housing assembly can be configured to be welded together.

[0031] The battery pack housing can be configured such that the size of the battery pack housing assembly is increased in the second direction by sequentially connecting them.

[0032] The battery pack housing assembly can be configured to be mounted directly on the vehicle chassis.

[0033] Furthermore, this disclosure provides a vehicle that includes a battery pack according to this disclosure.

[0034] Additionally, this disclosure may provide a vehicle comprising: a cell array including a plurality of battery cells; a battery pack housing assembly formed by arranging a plurality of battery pack housings configured to accommodate at least one of the cell arrays; and an exhaust valve configured to exhaust gases generated from the battery cells to the outside, wherein the cell array is configured to be inserted into the battery pack housing in a first direction, the battery pack housing is configured to be connected in a second direction perpendicular to the first direction, and the battery pack housing assembly is configured to be directly mounted on the chassis of the vehicle.

[0035] Beneficial effects

[0036] According to one aspect of this disclosure, the housing assembly and / or side members constituting the battery pack can be directly attached to the vehicle chassis, or can themselves serve as the vehicle chassis. That is, the cell array can be directly mounted on the vehicle chassis. This can increase energy density, improve space utilization, reduce weight and lower costs, while maintaining the vehicle's structure and dimensions.

[0037] In addition, according to another aspect of this disclosure, directional emission is caused to allow exhaust gases and the like generated by thermal events to be emitted in the downward direction of the battery pack, so that the pressure and heat energy inside the battery pack are effectively discharged, thereby delaying the chain reaction of heat transfer to adjacent cell arrays and thus enhancing safety.

[0038] Furthermore, according to another aspect of this disclosure, the structure of the battery pack housing can be simplified, and the housing can be modularized for ease of manufacturing. By sequentially combining multiple such modular battery pack housings, assembly is simplified, customization is possible to match various sizes for different vehicle types, and cost savings can be achieved through component commonality.

[0039] Furthermore, according to another aspect of this disclosure, the cell array can be inserted into the battery pack housing by a sliding movement method, thereby making assembly and connection convenient and simple. Additionally, when a defective cell array is accommodated, it can be easily replaced with another cell array.

[0040] Furthermore, according to another aspect of this disclosure, events such as fires or explosions caused by thermal runaway in vehicles comprising multiple battery packs can be prevented or delayed.

[0041] In addition, this disclosure may have various other effects that will be described in each embodiment, or may omit descriptions of effects that can be readily deduced by those skilled in the art. Attached Figure Description

[0042] The accompanying drawings illustrate preferred embodiments of the present disclosure and, together with the foregoing disclosure, serve 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.

[0043] Figure 1 This is a perspective view of the battery pack according to an embodiment of the present disclosure, viewed from the front.

[0044] Figure 2 This is a perspective view of the battery pack according to an embodiment of the present disclosure, viewed from the rear.

[0045] Figure 3 This is an exploded perspective view showing the battery pack in a separated state according to an embodiment of the present disclosure.

[0046] Figure 4 This is a perspective view showing a battery pack housing according to an embodiment of the present disclosure.

[0047] Figure 5 This is a front view showing a battery pack housing according to an embodiment of the present disclosure.

[0048] Figure 6 This is a view showing the state in which the cell array according to an embodiment of the present disclosure is inserted into the battery pack housing.

[0049] Figure 7 This is a view showing the state in which the cell array according to an embodiment of the present disclosure is inserted into the battery pack housing.

[0050] Figure 8 This is a view showing a state in which multiple battery pack housings are arranged according to an embodiment of the present disclosure.

[0051] Figure 9 This is a perspective view showing multiple battery pack housings and cell arrays according to embodiments of the present disclosure.

[0052] Figure 10 This is a perspective view showing a battery pack housing with an exhaust valve according to an embodiment of the present disclosure.

[0053] Figure 11 This is an exploded perspective view showing a battery pack housing with an exhaust valve according to an embodiment of the present disclosure.

[0054] Figure 12 This is a front view showing a battery pack housing equipped with an exhaust valve according to an embodiment of the present disclosure.

[0055] Figure 13 This is a perspective view showing a battery pack including a cap according to an embodiment of the present disclosure.

[0056] Figure 14This is a perspective view showing a battery pack including a cap according to another embodiment of the present disclosure.

[0057] Figure 15 This is a perspective view showing a battery pack including a busbar assembly according to an embodiment of the present disclosure, viewed from the front.

[0058] Figure 16 This is a perspective view showing a battery pack including a busbar assembly according to another embodiment of the present disclosure, viewed from the rear.

[0059] Figure 17 This is a perspective view showing the lower surface of the battery pack housing and the busbar assembly according to an embodiment of the present disclosure.

[0060] Figure 18 This is a view showing a busbar connector according to an embodiment of the present disclosure.

[0061] Figure 19 This is a view showing a busbar assembly disposed on the lower surface of a battery pack housing according to an embodiment of the present disclosure, viewed from above.

[0062] Figure 20 This is a view showing the state of connection of the cell array and busbar assembly according to an embodiment of the present disclosure.

[0063] Figure 21 This is a view showing a portion of a battery pack including a front connector according to an embodiment of the present disclosure.

[0064] Figure 22 This is a perspective view showing a battery pack including side members according to an embodiment of the present disclosure.

[0065] Figure 23 This is a perspective view showing a side member according to an embodiment of the present disclosure.

[0066] Figure 24 This is a front view showing the state in which the cell array according to an embodiment of the present disclosure is inserted into the battery pack housing.

[0067] Figure 25 This is a perspective view showing a cell array according to an embodiment of the present disclosure.

[0068] Figure 26 This is a perspective view showing a cell array according to an embodiment of the present disclosure, viewed from below.

[0069] Figure 27 This is an exploded perspective view of a cell array according to an embodiment of the present disclosure.

[0070] Figure 28 This is a perspective view showing an absorption member according to an embodiment of the present disclosure.

[0071] Figure 29 This is a perspective view showing an absorption member according to another embodiment of the present disclosure.

[0072] Figure 30 This is a perspective view showing corresponding absorption members mounted on an array of cells facing each other, according to an embodiment of the present disclosure.

[0073] Figure 31 This is a side cross-sectional view showing a state in which the cell array and absorption member facing each other are connected according to an embodiment of the present disclosure.

[0074] Figure 32 This is a schematic diagram of a vehicle including a battery pack according to an embodiment of the present disclosure. Detailed Implementation

[0075] Preferred embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. Before the description, it should be understood that the terminology used in the specification and appended claims should not be construed as limited to its general and dictionary meaning, but rather as being interpreted based on the meanings and concepts corresponding to the technical aspects of the present disclosure, on the basis of the principle that allows the inventors to appropriately define the terminology for the best interpretation.

[0076] Therefore, the embodiments described in this specification and the configurations shown in the accompanying drawings are only some of the most preferred embodiments of this disclosure and are not intended to fully represent the technical aspects of this disclosure. Therefore, it should be understood that various equivalents and modifications can be made thereto when this application is filed.

[0077] Furthermore, this disclosure includes various embodiments. For each embodiment, repeated descriptions of substantially the same or similar configurations will be omitted, and the differences will be primarily described.

[0078] Additionally, to aid in understanding this disclosure, the accompanying drawings are not shown to scale, but the dimensions of some components may be exaggerated. Furthermore, in different embodiments, the same reference numerals may be assigned to the same components.

[0079] Although terms like "first," "second," etc., are used to describe various components, it is obvious that these components are not limited by these terms. These terms are only used to distinguish one component from another, and unless explicitly stated otherwise, it is obvious that a first component can be a second component.

[0080] Throughout the instruction manual, unless explicitly stated otherwise, each part may be singular or plural.

[0081] In the following text, when any configuration is set on the “upper (or lower)” or “top (or bottom)” of a component, it can mean not only that any configuration is set to contact the upper (or lower) surface of the component, but also that other configurations can be inserted between the component and any configuration set above (or below) the component.

[0082] Additionally, when describing a component as "connected," "joined," or "in contact" with another component, the components may be directly connected or in contact with each other. However, it should be understood that other components may be "inserted" between each component, or each component may be "connected," "joined," or "in contact" with another component.

[0083] As used herein, singular expressions include plural expressions unless the context clearly indicates otherwise. In this application, the terms “comprising” or “including” should not be construed as necessarily including all the various components or steps described in the specification, but should be construed as excluding some components or steps, or including additional components or steps.

[0084] Throughout the instruction manual, when “A and / or B” is mentioned, it can mean A, B or A and B, unless explicitly stated otherwise.

[0085] Furthermore, in this specification, unless otherwise stated, the Y-axis direction of the stacked cell array is referred to as the front-back direction, the X-axis direction, which is a horizontal direction orthogonal to the stacking direction of such cell array, is referred to as the left-right direction, and the Z-axis direction, which is orthogonal to the XY plane, is referred to as the up-down direction (vertical direction). In addition, the left-right direction, the front-back direction, and the up-down direction can be referred to as the first direction, the second direction, and the third direction, respectively.

[0086] Furthermore, directional terms such as up, down, left, right, front, and back may be used in this disclosure, but these terms are merely for ease of description and it will be apparent to those skilled in the art that these terms may vary depending on the position, arrangement, or rotation of the reference object or the position of the observer.

[0087] Figure 1 This is a perspective view of the battery pack 10 according to an embodiment of the present disclosure, viewed from the front (+Y axis direction). Figure 2 This is a perspective view of the battery pack 10 according to an embodiment of the present disclosure, viewed from the rear (-Y axis direction). Figure 3 This is an exploded perspective view showing the battery pack 10 in a separated state according to an embodiment of the present disclosure.

[0088] Reference Figures 1 to 3According to embodiments of the present disclosure, the battery pack 10 may include a cell array 100, a battery pack housing assembly 200, a cap 300, a side member 400, a busbar assembly 500, and an exhaust valve 600.

[0089] The cell array 100 may include a plurality of battery cells 110. The cell array 100 may also include a module cover 120. In this case, according to the embodiment, the cell array 100 may be defined as a battery module.

[0090] Multiple cell arrays 100 can be configured. Multiple cell arrays 100 can be stacked on top of each other. Multiple cell arrays 100 can be stacked in a horizontal direction. Cell arrays 100 can have various structures, and multiple cell arrays 100 can be stacked in various ways. The number and stacking method of multiple cell arrays 100 can be designed in various ways according to the size of the battery housing space of the vehicle to which they are applied.

[0091] The battery pack housing assembly 200 may have the form in which a plurality of battery pack housings 210 are arranged. Each battery pack housing 210 may be configured to accommodate at least one cell array 100. Specifically, an internal space is formed within the battery pack housing 210, and the battery pack housing 210 may be configured to accommodate the cell array 100 within the internal space. Multiple battery pack housings 210 may be provided. The multiple battery pack housings 210 may be arranged side-by-side in one direction.

[0092] According to an embodiment, the battery pack housing assembly 200 may include a first battery pack housing 210, a second battery pack housing 220 disposed adjacent to the first battery pack housing 210, a third battery pack housing 230 disposed adjacent to the second battery pack housing 220, and a fourth battery pack housing 240 disposed adjacent to the third battery pack housing 230. In other words, the first battery pack housing 210, the second battery pack housing 220, the third battery pack housing 230, and the fourth battery pack housing 240 may be arranged sequentially in one direction (X-axis direction). However, the number of battery pack housings 210 constituting the battery pack housing assembly 200 is not limited to the above embodiment and can be designed in various ways according to the size of the battery housing space in the vehicle.

[0093] The first battery pack housing 210, the second battery pack housing 220, the third battery pack housing 230, and the fourth battery pack housing 240 have substantially the same structure and shape, and for ease of description, the features of the first battery pack housing 210, the second battery pack housing 220, the third battery pack housing 230, and the fourth battery pack housing 240 will be defined and described as battery pack housing 210.

[0094] In this embodiment, the battery pack housing assembly 200 can be directly mounted on the vehicle chassis, or the battery pack housing assembly 200 itself can be the vehicle chassis. That is, the cell array 100 can be configured to be directly inserted into and / or mounted on the vehicle chassis (e.g., the battery pack housing assembly 200).

[0095] At this time, the cell array 100 can be configured to be inserted into the battery pack housing 210 in a first direction (Y-axis direction), and multiple battery pack housings 210 can be configured to be connected in a second direction (X-axis direction) perpendicular to the first direction.

[0096] Figure 4 This is a perspective view showing a battery pack housing 210 according to an embodiment of the present disclosure. Figure 5 This is a front view showing a battery pack housing 210 according to an embodiment of the present disclosure. Figure 6 This is a view showing the state in which the cell array 100 according to an embodiment of the present disclosure is inserted into the battery pack housing 210. Figure 7 This is a view showing the state in which the cell array 100 according to an embodiment of the present disclosure is inserted into the battery pack housing 210.

[0097] First, refer to Figure 4 The battery pack housing 210 may have openings 215, 216 formed on the front or rear surface. This embodiment illustrates that openings 215, 216 are formed on the front and rear surfaces of the battery pack housing 210, respectively. The battery pack housing 210 may have openings in the longitudinal direction (e.g., Figure 4 A rectangular tubular shape with an opening in the Y-axis direction. For example, the battery pack housing 210 may include a cover facing left (e.g., Figure 4 The left plate 211 of one surface (in the -X axis direction) and the covering surface in the right direction (e.g., Figure 4 The right plate 212 of one surface (in the +X axis direction) covers the downward direction (e.g., Figure 4 The lower plate 214 of one surface (in the -Z axis direction) and the covering surface in the upward direction (e.g., Figure 4 The upper plate 213 is located on one surface (in the +Z axis direction). Furthermore, the left plate 211, right plate 212, lower plate 214, and upper plate 213 can be configured to be integral with each other. In this case, the battery pack housing 210 can be open in the front-rear direction. That is, the battery pack housing 210 can include both a front opening 215 and a rear opening 216.

[0098] According to the embodiments described above in this disclosure, the cell array 100 can be accommodated in or removed from the internal space of the battery pack housing 210 through the front opening 215 and / or the rear opening 216. Therefore, the cell array 100 can be easily assembled into the battery pack housing 210, and when a defective cell array 100 is accommodated, it can be easily replaced with another cell array 100. Therefore, after-sales service (A / S) is possible even in CTC (Completely Tendered) form.

[0099] According to another embodiment, although not shown in the figures, the battery pack housing 210 may be only in the front direction (e.g., Figure 4 (in the +Y axis direction) and the back direction (e.g., Figure 4 The battery pack housing 210 is open in one of the directions (Y-axis direction). For example, the battery pack housing 210 may also include a rear panel (not shown) covering a surface facing rearward. In this case, the front direction of the battery pack housing 210 may be open. That is, the battery pack housing 210 may include a front opening 215, and the cell array 100 can be accommodated in or removed from the interior space of the battery pack housing 210 through the front opening 215.

[0100] According to another embodiment, although not shown in the figures, the battery pack housing 210 can be configured as a U-shaped frame. When the battery pack housing 210 is configured as a U-shaped frame, it can be configured to cover two side surfaces and a lower surface of the cell array 100. For example, the battery pack housing 210 may include a left plate 211 covering a surface facing left of the cell array 100, a right plate 212 covering a surface facing right, and a lower plate 214 covering a surface facing downward of the cell array 100. Furthermore, the left plate 211, right plate 212, and lower plate 214 can be configured to be integral with each other. In this case, the battery pack housing 210 can be configured in both the upward and backward directions (e.g., Figure 4 It is open in the Y-axis direction.

[0101] At this time, the battery pack housing 210 may also include a top plate (not shown). The top plate may be configured to form a surface facing upwards towards the battery pack housing 210. When the battery pack housing 210 is configured as a U-shaped frame, the top plate may be connected to the open upward side of the battery pack housing 210. The top plate may be welded to the U-shaped frame of the battery pack housing 210. However, the top plate may be omitted as needed. For example, the battery pack housing 210 may be provided with an open upper side. However, the shape and / or structure of the battery pack housing 210 is not limited to the above-described embodiments and can be designed in various ways.

[0102] Reference Figures 4 to 6The lower plate 214 of the battery pack housing 210 can form a step. That is, the lower plate 214 of the battery pack housing 210 can be divided into multiple regions based on the X-axis, and can have different heights according to the regions. The lower plate 214 of the battery pack housing 210 can be divided into a downwardly protruding edge portion 214a, a center portion 214c positioned above the edge portion 214a, and a middle portion 214b positioned between the edge portion 214a and the center portion 214c and positioned above the center portion 214c.

[0103] The edge portion 214a, the center portion 214c, and the middle portion 214b have a flat plate shape in the horizontal direction, and a connecting portion 214d can be provided. The connecting portion 214d connects the edge portion 214a, the center portion 214c, and the middle portion 214b between the edge portion 214a and the center portion 214c, and is formed to be inclined from the horizontal plane at a predetermined angle.

[0104] The edge portion 214a of the lower plate 214 has the lowest height within the lower plate 214, thus allowing direct contact with the bottom surface of the vehicle. Furthermore, the edge portion 214a is a downwardly projecting portion and can guide the sliding movement of the cell array 100. The middle portion 214b of the lower plate 214 has the highest height within the lower plate 214 and can therefore be configured to allow the cell array 100 to be mounted thereon. The center portion 214c of the lower plate 214 can be configured to connect to the exhaust valve 600, which will be described later.

[0105] The shape of the lower plate 214 can be symmetrical with respect to the X-axis. The central portion 214c of the lower plate 214 can be positioned at the center with respect to the X-axis. The middle portion 214b of the lower plate 214 can be composed of plates extending to the left and to the right from the central portion 214c. The edge portion 214a of the lower plate 214 can be composed of plates extending to the left and to the right from the middle portion 214b.

[0106] According to the above embodiments of this disclosure, a step is formed in the lower plate 214 of the battery pack housing 210, which facilitates the housing and positioning of the cell array 100. Furthermore, when the exhaust valve 600, described later, is mounted on the lower plate 214 (e.g., the center portion 214c) of the battery pack housing 210, the exhaust valve 600 can be protected from external influences by preventing direct contact with a surface outside the battery pack housing 210 (e.g., the bottom surface of the vehicle).

[0107] The battery pack housing 210 may be made of a rigid and heat-resistant metallic material to physically or chemically protect the cell array 100 housed inside the battery pack housing 210. For example, the battery pack housing 210 may include at least one of aluminum alloy, stainless steel, titanium alloy, and amorphous metal. For example, the battery pack housing 210 may include an aluminum alloy.

[0108] According to the above embodiments of the present disclosure, each battery pack housing 210 constituting the battery pack housing assembly 200 forms an independent space and includes a thick and rigid material (e.g., aluminum), so that the battery pack housing 210 itself serves as a partition wall, thereby preventing heat transfer to the cell array in another adjacent battery pack housing.

[0109] The battery pack housing 210 can be formed by one or more processes selected from extrusion, forging, pressing, and casting. According to an embodiment, the battery pack housing 210 can be formed by extrusion. For example, when the battery pack housing 210 has a hollow structure including a front opening 215 and a rear opening 216, it can be extruded into a rectangular tubular shape. According to the above embodiments of this disclosure, it may be effective to produce the battery pack housing 210 with a simple manufacturing process, a consistent shape, and a long extended length. (Main reference) Figure 6 The cell array 100 can be inserted into the battery pack housing 210 in a first direction (Y-axis direction). The cell array 100 can be inserted into the battery pack housing 210 only in the first direction. Unlike typical conventional battery pack housings, the battery pack housing can be configured not to be inserted in a second direction (X-axis direction) perpendicular to the first direction. That is, the battery pack housing 210 can be configured to allow multiple cell arrays 100 to be inserted therein along the first direction. For example, multiple cell arrays 100 can be inserted into the battery pack housing 210 in the front-rear direction through the front opening 215 and / or rear opening 216 of the battery pack housing 210. In other words, the battery pack housing 210 can have a structure in which the cell arrays 100 are inserted in rows within the battery pack housing 210.

[0110] The cell array 100 can be configured to slide into the battery pack housing 210 through the front opening 215 and / or the rear opening 216. That is, multiple cell arrays 100 can be slidably inserted into the battery pack housing 210 in a first direction. The cell arrays 100 can be inserted into the battery pack housing 210 in a row. The slidably inserted cell arrays 100 can be in close contact with each other. The cell arrays 100 inserted into the battery pack housing 210 can be configured to be in direct contact with each other without a predetermined gap.

[0111] Conventionally, battery modules are assembled by vertically mounting each on a battery pack housing, and gaps should be provided for assembly between the battery modules. According to this disclosure, the cell array 100 can be assembled without gaps between it by inserting the cell array 100 in a row into the battery pack housing 210.

[0112] According to the embodiments described above, the cell array 100 can be inserted into the battery pack housing 210 via a sliding motion, thereby facilitating and simplifying assembly and connection. Furthermore, when a defective cell array 100 is present, it can be easily replaced with another cell array 100. Therefore, even in CTC (Completely Tendered) form, after-sales service is possible. Moreover, the cell arrays 100 can be in close contact with each other, thereby maximizing energy density.

[0113] At this point, the number of cell arrays 100 inserted into the battery pack housing 210 can be designed in various ways. For example, refer to Figure 6 and Figure 7 Three cell arrays 100 can be inserted into the battery pack housing 210. That is, considering the battery insertion space within the vehicle, the battery pack housing 210 can be manufactured with a length that allows for the insertion of N cell arrays 100 when N cell arrays 100 can be inserted in the Y-axis direction. The length of the battery pack housing 210 is adjustable, allowing for flexibility in the dimensions of each vehicle, thus allowing the battery pack 10 to be manufactured in flexible sizes.

[0114] Main reference Figure 7 The horizontal length (X-axis length) T2 of the battery pack housing 210 can correspond to the horizontal length (X-axis length) T1 of the cell array 100. The horizontal length (X-axis length) T2 of the battery pack housing 210 can be substantially the same as the horizontal length (X-axis length) T1 of the cell array 100, or it can be formed to be slightly longer than the horizontal length (X-axis length) T1 of the cell array 100 to facilitate insertion and installation.

[0115] The height (Z-axis length) H2 of the battery pack housing 210 can correspond to the height (Z-axis length) H1 of the cell array 100. The height (Z-axis length) H2 of the battery pack housing 210 can be substantially the same as the height (Z-axis length) H1 of the cell array 100, or it can be formed to be slightly longer than the height (Z-axis length) H1 of the cell array 100 to facilitate insertion and installation.

[0116] The vertical length (Y-axis length) L2 of the battery pack housing 210 can correspond to N times the vertical length (Y-axis length) L1 of the cell array 100 (N: the number of inserted cell arrays 100). The vertical length (Y-axis length) L2 of the battery pack housing 210 can be substantially equal to N times the vertical length (Y-axis length) L1 of the cell array 100, or it can be formed to be slightly longer than N times the vertical length (Y-axis length) L1 of the cell array 100 to facilitate insertion and installation. For example, refer to... Figure 7When the three cell arrays 100 are configured to be inserted into the battery pack housing 210, the vertical length (Y-axis length) L2 of the battery pack housing 210 can be substantially equal to three times the vertical length (Y-axis length) L1 of the cell arrays 100.

[0117] According to the embodiments described above in this disclosure, the battery pack housing 210 is sized and lengthened to correspond to the cell array 100, and can be configured to extend longer in a first direction, allowing the cell array 100 to be inserted in that direction. This simplifies the structure of the battery pack housing 210 and allows for modularity in the battery pack housing 210 for easy manufacturing. Such a modular battery pack housing 210 can be adapted to vehicles of various sizes.

[0118] Figure 8 This is a view showing the state in which a plurality of battery pack housings 210 are arranged according to an embodiment of the present disclosure. Figure 9 This is a perspective view showing a plurality of battery pack housings 210 and cell arrays 100 according to embodiments of the present disclosure.

[0119] Multiple battery pack housings 210 can be configured. These multiple battery pack housings 210 can be connected in one direction. In this case, the configuration with multiple battery pack housings 210 can be defined as a battery pack housing assembly 200. The multiple battery pack housings 210 can be configured to be connected in a second direction (X-axis direction) perpendicular to the first direction. The multiple battery pack housings 210 can be stacked in the second direction.

[0120] At this point, the number of battery pack housings 210 constituting the battery pack housing assembly 200 can be designed in various ways. That is, when considering that the battery insertion space in the vehicle can accommodate M battery pack housings 210 (or cell array 100) in the X-axis direction, the M battery pack housings 210 can be configured to be arranged. For example, referring to... Figure 8 and Figure 9 Four battery pack housings 210 can be arranged. For example, the battery pack housing assembly 200 may include a first battery pack housing 210, a second battery pack housing 220, a third battery pack housing 230, and a fourth battery pack housing 240. The first battery pack housing 210, the second battery pack housing 220, the third battery pack housing 230, and the fourth battery pack housing 240 may be arranged sequentially in the X-axis direction. The number of battery pack housings 210 can be adjusted in this way, thereby making the size of each vehicle flexible, and thus allowing the battery pack 10 to be manufactured in a flexible size.

[0121] Multiple battery pack housings 210 can be joined and integrated. The multiple battery pack housings 210 constituting the battery pack housing assembly 200 can be configured to be joined to each other by welding. For example, laser welding, ultrasonic welding, friction stir welding, etc., can be used, but various other joining methods can be applied. Multiple battery pack housings 210 arranged side-by-side can be configured to be welded together at a 1:1 ratio. (See reference...) Figure 8 The right plate 212 of the first battery pack housing 210 and the left plate 211 of the second battery pack housing 220, which are facing each other, can be welded to each other. The welded portion W can extend relatively long along the two side plates of the battery pack housing 210 in the Y-axis direction.

[0122] According to the embodiments described above in this disclosure, the length and dimensions of the battery pack housing assembly 200 can be configured to expand in a second direction by sequentially connecting a plurality of battery pack housings 210. Furthermore, the use of welding methods allows for convenient and simplified connection and assembly. By connecting the modular battery pack housings 210, the dimensions can be flexibly adjusted according to various vehicle sizes.

[0123] Figure 10 This is a perspective view showing a battery pack housing 210 provided with an exhaust valve 600 according to an embodiment of the present disclosure. Figure 11 This is an exploded perspective view showing a battery pack housing 210 provided with an exhaust valve 600 according to an embodiment of the present disclosure. Figure 12 This is a front view showing a battery pack housing 210 equipped with an exhaust valve 600 according to an embodiment of the present disclosure.

[0124] Reference Figures 10 to 12 The battery pack 10 may also include at least one vent valve 600, which is configured to pass through at least one vent hole 217 formed on one surface of the battery pack housing 210.

[0125] The vent valve 600 can be configured to pass through the lower plate 214 of the battery pack housing 210. The vent valve 600 can be configured to pass through the center portion 214c of the lower plate 214. The vent hole 217 can be formed in the center portion 214c of the lower plate 214 of the battery pack housing 210. That is, the vent valve 600 can be connected and fixed to the lower plate 214 by passing through the vent hole 217.

[0126] Multiple vent valves 600 can be connected within the battery pack housing 210. For example, the multiple vent valves 600 can be arranged along the Y-axis direction. The multiple vent valves 600 can be configured to be spaced apart at predetermined intervals. Similarly, multiple vent holes 217 can be provided, and the multiple vent holes 217 can be arranged in the Y-axis direction corresponding to the positions of the vent valves 600. For example, refer to... Figure 11Five vent valves 600 can be connected to a battery pack housing 210 and can form five vent holes 217.

[0127] Conventionally, the battery pack casing is configured to discharge exhaust gases to the side, and therefore, when exhaust gases are discharged toward the interior components of the vehicle, the stability of other components is problematic. According to the above-described embodiments of this disclosure, exhaust gases generated by thermal events can be discharged downwards from the battery pack 10 so as not to be obstructed or blocked by structures such as the vehicle body or chassis adjacent to the battery pack 10.

[0128] Therefore, exhaust gases can be smoothly and quickly released to the outside of the vehicle before heat accumulates due to the exhaust materials inside the battery pack 10. As the pressure and heat inside the battery pack 10 are effectively released, the chain reaction of heat transfer to adjacent cell arrays 100 may be delayed, thereby enhancing safety.

[0129] The exhaust valve 600 is positioned adjacent to the battery cell 110 and / or electrode leads 111 to minimize heat transfer to the adjacent battery cell 110. The edge portion 214a of the lower plate 214 has the lowest height within the lower plate 214 and can directly contact the bottom surface of the vehicle. At this time, the central portion 214c, which is connected to the exhaust valve 600, has a higher height than the edge portion 214a, thereby preventing the exhaust valve 600 from directly contacting the bottom surface of the vehicle. Therefore, damage to the exhaust valve 600 due to direct contact with the bottom surface of the vehicle can be prevented.

[0130] The middle portion 214b of the lower plate 214 has the highest height within the lower plate 214, and can therefore be configured to allow the cell array 100 to be placed thereon. The central portion 214c has a lower height than the middle portion 214b, thereby preventing the cell array 100 from being lifted by the exhaust valve 600.

[0131] According to this disclosure, when thermal runaway occurs in the battery cell 110, the gas or flame generated inside the battery cell 110 can be discharged to the outside of the cell array 100 through the lower part of the battery cell 110. Specifically, directional venting can be initiated downwards from the cell array 100. The gas or flame generated in the battery cell 110 is not discharged through the upper part of the battery cell 110, but can be directly discharged through the vent valve 600 located at the lower part of the battery cell 110 adjacent to the battery cell 110, thereby enhancing safety. Cooling of the battery cell 110 can be performed at the upper end opposite to the vent valve 600, thereby avoiding interference with the downward venting.

[0132] Figure 13 This is a perspective view showing a battery pack 10 including a cap 300 according to an embodiment of the present disclosure. Figure 14This is a perspective view showing a battery pack 10 including a cap 300 according to another embodiment of the present disclosure.

[0133] The battery pack 10 may also include a cap 300 configured to cover the openings 215, 216 of the battery pack housing 210. That is, the cap 300 may cover a surface facing the front and / or rear surface of the battery pack housing 210. According to an embodiment, the front opening 215 and the rear opening 216 are formed in the battery pack housing 210, and the cap 300 may include a front cap 310 configured to cover the front opening 215 and a rear cap 320 configured to cover the rear opening 216.

[0134] The shape of the cap 300 can be substantially the same as the front shape of the battery pack housing assembly 200. That is, the cap 300 can be configured to cover multiple openings 215 or 216 of the multiple battery pack housings 210 constituting the battery pack housing assembly 200. The horizontal length (X-axis length) of the cap 300 can be substantially the same as the horizontal length (X-axis length) of the battery pack housing assembly 200. For example, refer to... Figure 13 When the battery pack housing assembly 200 consists of four battery pack housings 210, the horizontal length (X-axis length) of the cap 300 can be approximately four times the horizontal length (X-axis length) of the battery pack housing 210. The height (Z-axis length) of the cap 300 can be approximately the same as the height (Z-axis length) of the battery pack housing assembly 200 (battery pack housing 210). The lower surface of the cap 300 can have a vertically protruding or recessed shape, similar to the lower plate 214 of the battery pack housing 210.

[0135] The cap 300 may include a plurality of holes 301. The number of holes 301 formed in the cap 300 may correspond to the number of battery pack housings 210 constituting the battery pack housing assembly 200. For example, refer to Figure 13 When the battery pack housing assembly 200 is composed of four battery pack housings 210, the four holes 301 can be configured to be spaced apart from each other in the X-axis direction. Additionally, each hole 301 can be formed at a position corresponding to an opening 215 or 216 in each battery pack housing 210. Specifically, each hole 301 can be formed at a position corresponding to a busbar connector 520 connected to each battery pack housing 210. The busbar connector 520 connected to each battery pack housing 210 can pass through the hole 301 to connect to the outside of the battery pack housing 210.

[0136] The cap 300 can be configured to attach to and detach from the battery pack housing 210. According to an embodiment, the cap 300 may include an adhesive disposed on an edge that contacts the battery pack housing 210. In this case, the adhesive strength is suitably from about 0.1 gf / 25 mm to 500 gf / 25 mm, and more preferably from 1 gf / 25 mm to 100 gf / 25 mm. This is less than the adhesive strength of a typical adhesive (1,500 gf / 25 mm), thus distinguishing it from typical adhesives and allowing for easy attachment and detachment. However, the construction of the cap 300 is not limited to the above embodiment, and if the cap 300 is configured to attach to and detach from the battery pack housing 210, it can be designed in various ways.

[0137] According to the embodiments described above in this disclosure, the cap 300 covers the front and rear surfaces of the battery pack housing 210, thereby enhancing the structural rigidity of the cell array 100 and preventing exhaust gases from being transferred to another battery pack housing 210 through the front or rear surfaces of the battery pack housing 210. The cap 300 can be attached to and detached from the battery pack housing 210, thereby allowing for easy separation from the battery pack housing 210 and facilitating easy replacement of the cell array 100 within the battery pack housing 210.

[0138] According to another embodiment, refer to Figure 14 The front cap 310 and the rear cap 320 may include a plurality of caps 300, which are configured to cover a plurality of battery pack housings 210 respectively. That is, a cap 300 may individually cover an opening 215 or 216 of a battery pack housing 210. For example, see reference Figure 14 The front cap 310 may include a first front cap 311 covering the first battery pack housing 210, a second front cap 312 covering the second battery pack housing 220, a third front cap 313 covering the third battery pack housing 230, and a fourth front cap 314 covering the fourth battery pack housing 240. The rear cap 320 may consist of four caps in the same manner.

[0139] At this point, the shape of the cap 300 can be substantially the same as the front shape of the battery pack housing 210. The horizontal length (X-axis length) of the cap 300 can be substantially the same as the horizontal length (X-axis length) of the battery pack housing 210. The height (Z-axis length) of the cap 300 can be substantially the same as the height (Z-axis length) of the battery pack housing assembly 200 (battery pack housing 210). The lower surface of the cap 300 can have protruding and concave structures formed in the same manner as the lower plate 214 of the battery pack housing 210.

[0140] The cap 300 may include at least one hole 301. The hole 301 may be formed at a location corresponding to an opening in the battery pack housing 210. Specifically, the hole may be formed at a location corresponding to a busbar connector 520 connected to the battery pack housing 210. The busbar connector 520 connected to the battery pack housing 210 may pass through the hole 301 to connect to the outside of the battery pack housing 210.

[0141] According to the embodiments described above in this disclosure, a separate cap 300 can be provided to cover each battery pack housing 210, thereby allowing for individual attachment and removal. This allows only the cap 300 of the battery pack housing 210 with the cell array 100 that needs to be replaced to be attached and removed. Furthermore, the standardized cap 300 can be mass-produced without adjusting the length or number of holes 301 according to vehicle size, thus effectively enabling mass production and cost reduction, and offering the advantage of component commonality.

[0142] Figure 15 This is a perspective view showing a battery pack 10 including a busbar assembly 500 according to an embodiment of the present disclosure, viewed from the front. Figure 16 This is a perspective view showing a battery pack 10 including a busbar assembly 500 according to an embodiment of the present disclosure, viewed from the rear. Figure 17 This is a perspective view showing the lower surface of the battery pack housing and the busbar assembly 500 according to an embodiment of the present disclosure. Figure 18 This is a view showing a busbar connector 520 according to an embodiment of the present disclosure. Figure 19 This is a view showing a busbar assembly 500 disposed on the lower surface of a battery pack housing according to an embodiment of the present disclosure, viewed from above. Figure 20 This is a view showing the connection state of the cell array 100 and the busbar assembly 500 according to an embodiment of the present disclosure. Figure 21 This is a view showing a portion of a battery pack 10 including a front connector 530 according to an embodiment of the present disclosure.

[0143] For ease of description, Figure 17 and Figure 19 This is a view omitting the remaining parts of the battery pack housing 210 except for the lower plate 214.

[0144] The busbar assembly 500 can be configured to be electrically connected to the electrode leads 111 of the battery cell 110. The busbar assembly 500 can be configured to allow the electrode leads 111 of multiple battery cells 110 to be interconnected. More specifically, the busbar assembly 500 can be configured to support the electrode leads 111, facilitate the interconnection of the electrode leads 111, and enable the sensing of voltage from the electrode leads 111, etc. The busbar assembly 500 can be configured to achieve a high-voltage connection.

[0145] The busbar assembly 500 may include busbar terminals 510, busbar connectors 520, and front connectors 530. Busbar terminals 510 may electrically connect two or more electrode leads 111. Busbar terminals 510 may electrically connect two or more electrode leads 111 within a battery pack housing 210.

[0146] Reference Figure 20 Each battery cell 110 may include electrode leads 111. The electrode leads 111 of the battery cell 110 include a positive electrode lead 111a and a negative electrode lead 111b, and the positive electrode lead 111a and the negative electrode lead 111b may be configured to be spaced apart from each other on the lower surface of the battery cell 110. The electrode leads 111 may be configured to protrude downwards from the lower surface of the battery cell 110. The specific structure and configuration of the battery cell will be described later.

[0147] The busbar terminal 510 is located at the lower part of the battery cell 110, where the electrode leads 111 of the battery cell 110 are located, and can be configured to be connected to the electrode leads 111. The busbar terminal 510 can be located between the lower part of the battery cell 110 and the lower plate 214 of the battery pack housing 210. The busbar terminal 510 can be in vertical contact with multiple electrode leads 111, and can be connected and fixed to multiple electrode leads 111. At this time, the connection and fixing method between the electrode leads 111 and the busbar terminal 510 can use methods such as laser welding or ultrasonic welding.

[0148] According to another embodiment, although not shown in the figures, a slit hole (not shown) may be formed in the busbar terminal 510, and the electrode lead 111 may be inserted and soldered through the slit hole. However, the connection and fixing method between the electrode lead 111 and the busbar terminal 510 is not limited to the above embodiment, and various other fastening methods may be applied.

[0149] The busbar terminal 510 can be connected to multiple electrode leads 111 arranged along a first direction (Y-axis direction), which is the stacking direction of the battery cells 110. For example, refer to... Figure 20 The busbar terminal 510 can be connected to six electrode leads 111. However, the number of electrode leads 111 to which the busbar terminal 510 can be connected is not limited to the above embodiment and can be designed in various ways.

[0150] Multiple busbar terminals 510 can be aligned along a first direction (Y-axis direction), which is the stacking direction of the battery cells 110. The battery pack housing 210 may be provided with positive busbar terminals 511 that connect multiple positive leads 111a and negative busbar terminals 512 that connect multiple negative leads 111b. The positive busbar terminals 511 and negative busbar terminals 512 can be aligned along the first direction (Y-axis direction) respectively.

[0151] At this time, the positive busbar terminal 511 and the negative busbar terminal 512 can be connected to the electrode leads 111 of different battery cells 110. That is, the positive busbar terminal 511 can be connected to the electrode leads 111 from the first to the sixth battery cells 110, and the negative busbar terminal 512 can be connected to the electrode leads 111 from the fourth to the ninth battery cells 110. According to the above embodiment of this disclosure, all battery cells 110 housed in the battery pack housing 210 can be electrically connected.

[0152] Busbar terminal 510 may include a metal such as copper. Busbar terminal 510 may have a thin and flat plate shape. For example, busbar terminal 510 may have a rectangular shape.

[0153] The busbar connector 520 can be electrically connected to the busbar terminals 510 disposed in different battery pack housings (e.g., 210, 220). That is, one end and the other end of the busbar connector 520 can be disposed in different battery pack housings (e.g., 210, 220).

[0154] Multiple busbar connectors 520 can be configured. For example, refer to... Figure 17 The busbar connector 520 may include a first connector 521 connecting the busbar terminals 510 of the second battery pack housing 220 and the third battery pack housing 230, a second connector 522 connecting the busbar terminals 510 of the first battery pack housing 210 and the fourth battery pack housing 240, a third connector 523 connecting the busbar terminals 510 of the third battery pack housing 230 and the fourth battery pack housing 240, and a fourth connector 524 connecting the busbar terminals 510 of the first battery pack housing 210 and the second battery pack housing 220. According to the above embodiments of this disclosure, all the busbar terminals 510 constituting the battery pack housing assembly 200 can be electrically connected.

[0155] Reference Figure 18The busbar connector 520 may include multiple bends. For example, the busbar connector 520 may include a first portion 5201 located below the battery cell 110 and extending in a first direction (Y-axis direction), a second portion 5202 extending from the first portion 5201 in a vertical direction (+Z-axis direction), a third portion 5203 extending from the second portion 5202 in a second direction (X-axis direction), a fourth portion 5204 extending again from the third portion 5203 in a vertical direction (-Z-axis direction), and a fifth portion 5205 extending from the fourth portion 5204 in the first direction (Y-axis direction).

[0156] Main reference Figure 19 In the enlarged view, the busbar connector 520 can be configured to pass through the hole 301 formed in the cap 300 to connect to the outside of the cap. That is, the middle portion of the busbar connector 520 can be disposed in the outward direction of the cap 300, and the edge portion can be disposed in the inward direction of the cap 300. For example, the first portion 5201 and the fifth portion 5205 of the busbar connector 520 can be disposed substantially in the inward direction of the cap 300, and the first portion 5201 and the fifth portion 5205 can pass through the hole 301 formed in the cap 300. Additionally, the second portion 5202, the third portion 5203, and the fourth portion 5204 of the busbar connector 520 can be disposed in the outward direction of the cap 300. The second portion 5202, the third portion 5203, and the fourth portion 5204 can be disposed parallel to the cap 300. According to the embodiment, the second portion 5202, the third portion 5203, and the fourth portion 5204 can contact the cap 300.

[0157] According to the above embodiments of this disclosure, the busbar connector 520 is configured to be externally connected, and therefore, in the event of a thermal event, a chain reaction of heat transfer through the busbar connector 520 to the adjacent battery pack housing 210 can be prevented, thereby enhancing safety.

[0158] The front connector 530 can be configured to connect to one or more electrode leads 111 and transmit sensing information to a control unit such as a battery management system (BMS). The front connector 530 can be disposed on the busbar connector 520. The front connector 530 can be electrically connected to the busbar connector 520. For example, the front connector 530 can be disposed on and electrically connected to the first connector 521.

[0159] The front connector 530 can be configured to pass through the cap 300. The front connector 530 may include a plate portion 531 disposed on the cap 300, a connector portion 532 protruding towards the front of the plate portion 531 and configured to connect to an external component (e.g., a control unit such as a BMS), and a fixing portion (not shown) configured to engage and secure to the battery pack housing 210. In this case, the plate portion 531 is configured to engage and secure to the cap 300 and may be disposed on the outside of the cap 300. The connector portion 532 may be disposed on the outside of the cap 300. The fixing portion may pass through the cap 300 to be positioned on a surface within the battery pack housing 210. The plate portion 531 can be engaged and secured by bolts and screws. However, the engagement and securing method is not limited to the above-described embodiment and can be designed in various ways.

[0160] Figure 22 This is a perspective view showing a battery pack 10 including a side member 400 according to an embodiment of the present disclosure. Figure 23 This is a perspective view showing a side member 400 according to an embodiment of the present disclosure.

[0161] The battery pack 10 may also include a side member 400. The side member 400 may be configured to be directly coupled to the battery pack housing assembly 200.

[0162] The side member 400 can be directly connected to both sides of the battery pack housing assembly 200. The side member 400 may include a first side member 410 disposed on the left side of the battery pack housing assembly 200 and a second side member 420 disposed on the right side of the battery pack housing assembly 200.

[0163] Reference Figure 23 The side member 400 may include a first side surface 401 configured to contact a surface of the battery pack housing 210 and a second side surface 402 configured to be coupled to the vehicle frame. In this embodiment, the side member 400 may be directly connected to the vehicle chassis. In another embodiment, the side member 400 may be the vehicle chassis itself. That is, the side member 400 may itself be the vehicle chassis.

[0164] Typically, battery modules are housed within battery pack 10, which is then assembled to the vehicle chassis. However, this increases the number of unnecessary components and is disadvantageous in terms of space utilization and energy efficiency. According to the embodiments described above, the side member 400 can be directly connected to the vehicle chassis, or it can itself serve as the vehicle chassis. This increases energy density, improves space utilization, and reduces costs, while maintaining the vehicle's structure and dimensions.

[0165] Furthermore, by adjusting the length and number of battery pack housings 210, the battery pack housing assembly 200 has a flexible size for each vehicle, while the side members 400 have the advantage of being component-compatible.

[0166] Side member 400 can be attached to a battery pack housing (e.g., 210, 240) located at the edge of battery pack housing assembly 200. For example, see reference... Figure 22 The first side member 410 can be connected to the first battery pack housing 210, and the second side member 420 can be connected to the fourth battery pack housing 240.

[0167] Figure 24 This is a front view showing the state in which the cell array 100 according to an embodiment of the present disclosure is inserted into the battery pack housing 210. Figure 25 This is a perspective view showing a cell array 100 according to an embodiment of the present disclosure. Figure 26 This is a perspective view showing a cell array 100 according to an embodiment of the present disclosure, viewed from below. Figure 27 This is an exploded perspective view of a cell array 100 according to an embodiment of the present disclosure. Figure 28 This is a perspective view showing the absorption member 140 according to an embodiment of the present disclosure. Figure 29 This is a perspective view showing an absorption member 140 according to another embodiment of the present disclosure. Figure 30 This is a perspective view showing corresponding absorption members 140 mounted on cell arrays 100 facing each other, according to an embodiment of the present disclosure. Figure 31 This is a side cross-sectional view showing the state in which the cell array 100 and the absorption member 140 facing each other are connected according to an embodiment of the present disclosure.

[0168] Reference Figures 24 to 31 The cell array 100 may include battery cells 110, module cover 120, and absorption member 140.

[0169] The battery cell 110 can be of various types. For example, the battery cell 110 may include at least one of pouch cell, cylindrical cell, and prismatic cell. However, for ease of description, the following description will focus on the case where the battery cell 110 is a pouch cell.

[0170] Multiple battery cells 110 can be configured. Multiple battery cells 110 can be stacked on top of each other. Battery cells 110 can have various structures, and multiple battery cells 110 can be stacked in various ways. Pads can be included between battery cells 110 to prevent movement of the battery cells. The pads can perform substantially the same function as the absorption member 140.

[0171] The battery cell 110 can have a structure in which multiple unit cells arranged in the order of positive plate, separator and negative plate, or multiple dual cells arranged in the order of positive plate, separator, negative plate, separator, positive plate, separator and negative plate, are stacked according to the battery capacity.

[0172] Electrode leads 111 can be disposed in battery cell 110. Electrode leads 111 are terminals exposed to the outside and connected to external devices, and can be made of conductive material. Electrode leads 111 may include a positive lead 111a and a negative lead 111b.

[0173] The electrode leads 111 can be configured to protrude downwards from the lower surface of the battery cell 110. The positive lead 111a and the negative lead 111b can be configured to be spaced apart from each other on the lower surface of the battery cell 110. The positive lead 111a and the negative lead 111b can each be electrically connected to a busbar terminal disposed on the lower side of the battery cell 110. However, the position and shape of the electrode leads 111 are not limited to the above embodiment and can be designed in various ways.

[0174] High-temperature gases, flames, sparks, etc. generated during thermal runaway in the battery cell 110 are likely to be ejected to the portion where the corresponding electrode lead 111 is located (e.g., the lower part of the battery cell 110). According to an embodiment of this disclosure, the electrode lead 111 is disposed on the lower side, thereby causing directional venting, so that when a thermal event occurs, the exhaust gases, etc., are discharged downwards.

[0175] At this time, the electrode lead 111 and the exhaust valve 600 can be arranged adjacent to each other. Therefore, exhaust gases and the like that discharged downwards can be quickly discharged to the outside of the battery pack 10 through the exhaust valve 600 located at the bottom. By minimizing the path of exhaust gases and the like to the exhaust valve 600 within the battery pack housing 210, heat transfer within the battery pack housing 210 or between battery pack housings 210 can be prevented.

[0176] The module cover 120 can be configured to protect and / or support the battery cells 110. Multiple battery cells 110 can be stacked and housed within the module cover 120. The module cover 120 surrounds at least a portion of the multiple battery cells 110, thereby protecting the battery cells 110 from external vibration or impact.

[0177] The module cover 120 may further include a top cover 121 covering the battery cell 110 from above, a front cover 124 covering the battery cell 110 from the front, and a rear cover 125 covering the battery cell 110 from the rear. The front cover 124 and the rear cover 125 cover the front and rear portions of the battery cell 100 within the cell array 100, thereby supplementing structural rigidity and responding to the expansion of the battery cell 100.

[0178] The module cover 120 may include support members 122, 123 supporting the battery cell 110 at its lower end. However, the support members 122, 123 may be configured such that at least a portion of the lower part of the battery cell 110 is not covered, and at least a portion of the lower part of the battery cell 110 is exposed to the outside. In other words, the electrode leads 111 disposed on the lower surface of the battery cell 110 may not be covered by the module cover 120.

[0179] According to the above embodiments of this disclosure, at least a portion of the lower part of the battery cell 110 is exposed, and therefore, when thermal runaway occurs in the battery cell 110, the gas or flame generated inside the battery cell 110 can be discharged to the outside of the cell array 100 through the lower part of the battery cell 110. Specifically, directional venting can be caused on the lower side of the cell array 100.

[0180] The support members 122 and 123 can be composed of a first rod 122 and a second rod 123 supporting the battery cell 110 at their lower ends on both sides (left and right). The first rod 122 and the second rod 123 can have a rod shape that extends relatively long in a first direction (Y-axis direction). The first rod 122 and the second rod 123 can be respectively provided on the left and right sides of the battery cell 110. That is, the battery cell 110 can be mounted on the first rod 122 and the second rod 123.

[0181] According to another embodiment, although not shown in the figures, the module cover 120 may include a bottom cover that covers the battery cell 110 from below and has an opening formed at the center excluding the edges.

[0182] The front cover 124 and the rear cover 125 can be configured to cover the entirety of the top cover 121, the battery cell 110, and the support members 122, 123. For example, refer to... Figure 27 The front cover 124 and the rear cover 125 may have shapes including portions that protrude downwards to correspond to the position and shape of the support members 122, 123 on the rectangular plate. In other words, the lower surfaces of the front cover 124 and the rear cover 125 may have shapes with protruding edges and concave middle portions. Additionally, refer to... Figure 24 The protruding edges of the front cover 124 and the rear cover 125, i.e., the portions where the first rod 122 and the second rod 123 are located, can be configured to be inserted into the edge portion 214a of the battery pack housing 210 and slide. The middle portions of the front cover 124 and the rear cover 125 can be inserted into the middle portion 214b and the center portion 214c.

[0183] According to the above embodiments of this disclosure, the cell array 100 can be guided to slide within the battery pack housing 210. Furthermore, movement of the cell array 100 within the battery pack housing 210 can be prevented, and the position of the cell array 100 can be fixed.

[0184] The structure and shape of the module cover 120 supporting the battery cell 110 are not limited to the above embodiments, and some parts of the module cover 120 can be removed to reduce the weight and volume of the module cover 120.

[0185] In this way, the module cover 120 can be configured to minimize its weight and volume while providing minimal protection and / or support for the battery cell 110. The module cover 120 can minimize weight and volume by exposing at least a portion of the battery cell 110. For example, refer to... Figure 25 and Figure 26 The module cover 120 may not cover at least a portion of the two side surfaces and / or the lower surface of the battery cell 110. That is, at least a portion of the two side surfaces and / or the lower surface of the battery cell 110 may be configured to be exposed. Therefore, the structural rigidity of the module cover 120 may be weaker than the structural rigidity of the battery pack housing 210.

[0186] According to the above embodiments of this disclosure, the battery cell 110 is protected and supported by the rigid battery pack housing 210, and the portion additionally covered by the module cover 120 can be minimized. According to this method, the battery cell 110 can be further accommodated in the space occupied by the module housing, battery pack housing, etc., of the cell array 100 within the battery pack 10, thus increasing space efficiency and improving battery capacity. Furthermore, energy density can be maximized, the weight of the battery pack 10 can be reduced, and costs can be lowered.

[0187] The module cover 120 can be manufactured, for example, by bending a metal sheet, and therefore, the module cover 120 can be manufactured integrally. When the module cover 120 is manufactured integrally, the joining process can be convenient and simplified. Alternatively, the module cover 120 can be provided separately and joined by welding or the like. However, the material of the module cover 120 is not limited to metal.

[0188] The top cover 121, front cover 124, rear cover 125, and support members 122, 123 constituting the module cover 120 can be connected and fixed to each other. For example, the top cover 121, the first rod 122, and the second rod 123 can have protrusions 126 projecting toward the front and rear surfaces, respectively. Additionally, the front cover 124 and the rear cover 125 can have first fixing holes 127 corresponding to the size and shape of the protrusions 126 at portions corresponding to them. In this case, the front cover 124 and the rear cover 125 can each have four first fixing holes 127 formed therein. Each protrusion 126 can be fitted into each corresponding first fixing hole 127. However, the size and shape of the multiple protrusions 126 and the first fixing holes 127 can be different from each other. The method of connecting and fixing the module cover 120 is not limited to the above embodiment, and various other fastening methods can be applied.

[0189] Absorption member 140 can be provided on front cover 124 and rear cover 125.

[0190] The absorbent member 140 can be directly connected to the module cover 120. Second fixing holes 144, corresponding to the size and shape of the protrusions 126 formed on the top cover 121 and support members 122, 123 of the module cover 120, can be provided at the portions corresponding to the protrusions 126. In this case, four second fixing holes 144 can be formed in the absorbent member 140. Each protrusion 126 can be fitted into each corresponding second fixing hole 144. However, the size and shape of the multiple second fixing holes 144 can be different from each other. The method of connecting and fixing the module cover 120 and the absorbent member 140 is not limited to the above embodiment, and various other fastening methods can be applied.

[0191] The absorption member 140 may include a front absorption member 140a disposed at the front of the battery cell 110 and a rear absorption member 140b disposed at the rear of the battery cell 110. The front absorption member 140a may be disposed on the front cover 124 and the rear absorption member 140b may be disposed on the rear cover 125.

[0192] Reference Figure 29 The corresponding absorption members 140 of the facing cell array 100 inserted into a battery pack housing 210 can face each other. The corresponding absorption members 140 of the facing cell array 100 inserted into a battery pack housing 210 can be configured to contact each other. That is, the rear absorption member 140b disposed at the front of the cell array 100 and the front absorption member 140a disposed at the rear of the cell array 100 can be configured to face each other. At least a portion of the rear absorption member 140b disposed at the front of the cell array 100 and the front absorption member 140a disposed at the rear of the cell array 100 can be in direct contact with each other.

[0193] In this manner, when the cell array 100 is slidably inserted into the battery pack housing 210, the cell array 100 inevitably comes into direct contact with each other. This process may result in collisions between the cell arrays 100 or movement of components within the cell array 100 or the battery cells 110. The absorbing member 140 of this disclosure can be configured to prevent movement of the battery cells 110 or components within the cell array 100 and to absorb impacts caused by collisions between the cell arrays 100. Additionally, the absorbing member 140 can offset or absorb assembly tolerances between the cell arrays 100. The absorbing member 140 covers the front and rear portions of the battery cells 100 within the cell array 100, thereby supplementing structural rigidity and responding to expansion of the battery cells 100.

[0194] The absorbing member 140 may include a vertical and flat main body 142 and a shock-absorbing part 141 extending from the main body 142.

[0195] The damping portion 141 can protrude outward from the main body portion 142. The damping portion 141 may be the portion that first contacts the adjacent cell array 100. For example, the damping portion 141 of the front absorption member 140a can protrude forward from the main body portion 142. The damping portion 141 of the rear absorption member 140b can protrude rearward from the main body portion 142.

[0196] According to the above embodiments of the present disclosure, when the shock-absorbing part 141 first contacts the adjacent cell array 100 and absorbs the impact caused by the contact, the impact applied to the battery cell 110 and internal components is reduced, thereby preventing the movement of the battery cell 110 and the like.

[0197] Multiple damping sections 141 can be provided. These multiple damping sections 141 can be evenly distributed across the entire main body 142. The multiple damping sections 141 can be arranged according to a specific pattern. For example, refer to... Figure 24 Multiple damping portions 141 can be arranged to be spaced apart at predetermined intervals in the upper, lower, left, and right directions. Here, the predetermined interval can be defined as an interval corresponding to or greater than the size of the damping portion 141. That is, the damping portion 141 disposed on the lower side can be positioned between the damping portions 141 disposed on the upper side based on the X-axis direction. For ease of description, the damping portion 141 can be defined as a protruding region, and the main body portion 142 between the damping portions 141 can be defined as a concave region. That is, the protruding regions and concave regions can be alternately arranged based on the same height. In other words, the protruding regions and concave regions can be alternately arranged based on the same Z-axis.

[0198] At this time, the arrangements of the damping portions 141 of the front absorbing member 140a and the rear absorbing member 140b can be different from each other. Specifically, the protruding and concave regions of the front absorbing member 140a and the rear absorbing member 140b can be arranged opposite to each other. That is, the protruding region of the front absorbing member 140a can face the concave region of the rear absorbing member 140b, and the concave region of the front absorbing member 140a can face the protruding region of the rear absorbing member 140b. In other words, the corresponding damping portions 141 of the front absorbing member 140a and the rear absorbing member 140b do not need to contact each other.

[0199] According to the above embodiments of this disclosure, when the cell array 100 within the battery pack housing 210 is in direct contact with each other, the shock-absorbing portion 141 of the front absorption member 140a contacts the main body portion 142 of the rear absorption member 140b, and the main body portion 142 of the front absorption member 140a contacts the shock-absorbing portion 141 of the rear absorption member 140b, so that the entire area of ​​the absorption member 140 can absorb the impact. That is, the impact absorption area is approximately twice the area of ​​the shock-absorbing portion 141, thus absorbing the impact more effectively.

[0200] The shock-absorbing part 141 may include an absorption pad 1412 disposed parallel to the main body 142, and connecting members 1411 and 1413 connecting the absorption pad 1412 and the main body 142. The absorption pad 1412 may be the part that directly contacts the facing cell array 100. The absorption pad 1412 may directly contact the absorption member 140 of the facing cell array 100. The absorption pad 1412 may directly contact the main body 142 of the facing cell array 100.

[0201] The connecting members 1411 and 1413 may be formed to extend from the main body 142 and be inclined at a predetermined angle from the main body 142 and the absorbent pad 1412. The connecting members 1411 and 1413 may be formed on both sides (left and right sides) of the absorbent pad 1412. According to another embodiment, the connecting members 1411 and 1413 may be formed on the upper and lower sides of the absorbent pad 1412.

[0202] An opening 145 may be formed in the portion of the main body 142 that overlaps with the portion where the damping portion 141 is provided. In other words, the portion of the main body 142 that overlaps with the portion where the damping portion 141 is provided may be omitted. When the shape of the opening 145 is deformed, the damping portion 141 may also be deformed.

[0203] The absorbent member 140 may include a material that is both rigid and elastic. For example, the absorbent member 140 may include at least one of materials such as plastic, rubber, silicone, aerogel, metal, and glass fiber reinforced plastic (GFRP). For example, the absorbent member 140 may include plastic.

[0204] According to the above embodiments of this disclosure, the impact caused by the contact between the battery cell array 100 will not prevent the shape of the absorption pad 1412 from temporarily concave inward.

[0205] According to another embodiment, the shock-absorbing portion 141 may be thicker than the main body portion 142. (See also...) Figure 29 The damping part 141 may be a separate component joined and fixed to the main body 142. That is, the main body 142 may include a material with high rigidity, while the damping part 141 may include a material with relatively low rigidity and high elasticity compared to the main body 142.

[0206] However, the shape and structure of the shock absorber 141 are not limited to the above-described embodiments, and can be designed in various ways.

[0207] Figure 32 This is a schematic diagram of a vehicle V including a battery pack 10 according to an embodiment of the present disclosure.

[0208] Reference Figure 32 A vehicle V according to an embodiment of the present disclosure may include a battery pack 10 according to an embodiment of the present disclosure, or a cell array 100 and a battery pack housing assembly 200 according to an embodiment of the present disclosure. The vehicle V according to the present disclosure may be, for example, an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle. The vehicle V includes four-wheeled vehicles and two-wheeled vehicles. According to an embodiment of the present disclosure, the vehicle V can operate by receiving power from the battery pack 10 or the cell array 100.

[0209] The present disclosure has been described above with reference to a limited number of embodiments and accompanying drawings, but the present disclosure is not limited thereto, and it will be apparent to those skilled in the art that various modifications and variations can be made to it within the scope of the technical aspects of the present disclosure and the appended claims and their equivalents.

Claims

1. A battery pack, the battery pack comprising: A cell array, the cell array comprising a plurality of battery cells; A battery pack housing assembly formed by arranging a plurality of battery pack housings configured to accommodate at least one of the cell arrays; as well as An exhaust valve, configured to release exhaust gases generated by the battery cell to the outside. The cell array is configured to be inserted into the battery pack housing in a first direction, and The battery pack housing is configured to be connected in a second direction perpendicular to the first direction.

2. The battery pack according to claim 1, in, The vent valve is configured to have at least one vent hole formed through a surface of the battery pack housing.

3. The battery pack according to claim 1, in, The vent valve is configured to pass through the lower plate of the battery pack housing.

4. The battery pack according to claim 1, in, The exhaust valves are configured to be multiple, and the multiple exhaust valves are configured to be spaced apart from each other in the first direction.

5. The battery pack according to claim 1, in, When a thermal event occurs in the battery cell, the vent valve guides the exhaust gas downwards.

6. The battery pack according to claim 1, in, The battery pack housing has a rectangular tubular shape, and the rectangular tubular shape has an opening formed on the front or rear surface facing the first direction.

7. The battery pack according to claim 1, in, The lower plate of the battery pack housing is configured to form a step.

8. The battery pack according to claim 7, in, The lower plate is divided into a downwardly protruding edge portion, a center portion positioned above the edge portion, and a middle portion positioned between the edge portion and the center portion and positioned above the center portion.

9. The battery pack according to claim 8, in, The exhaust valve is configured to pass through the center portion of the lower plate.

10. The battery pack according to claim 1, in, The cell array also includes a module cover configured to support the battery cells.

11. The battery pack according to claim 10, in, The battery cell includes electrode leads protruding downward from the lower surface of the battery cell, and The electrode leads are not covered by the module cover.

12. The battery pack according to claim 11, in, The electrode leads and the exhaust valve are arranged adjacent to each other.

13. The battery pack according to claim 1, in, When a thermal event occurs in the battery cell, the exhaust gas is discharged downwards and configured to be discharged to the outside of the battery pack through the exhaust valve.

14. The battery pack according to claim 1, in, The battery pack housing is configured to be formed by at least one of the processes of extrusion, forging, pressing and casting.

15. The battery pack according to claim 1, in, The battery pack housings that constitute the battery pack housing assembly are configured to be welded together.

16. The battery pack according to claim 1, in, The battery pack housing is configured such that the size of the battery pack housing assembly is increased in the second direction by sequentially connecting the components.

17. The battery pack according to claim 1, in, The battery pack housing assembly is configured to be mounted directly on the vehicle chassis.

18. A vehicle comprising a battery pack according to any one of claims 1 to 17.

19. A vehicle, the vehicle comprising: A cell array, the cell array comprising a plurality of battery cells; A battery pack housing assembly, formed by arranging a plurality of battery pack housings configured to accommodate at least one of the cell arrays; and An exhaust valve, configured to release exhaust gases generated by the battery cell to the outside. The cell array is configured to be inserted into the battery pack housing in a first direction. The battery pack housing is configured to be connected in a second direction perpendicular to the first direction, and The battery pack housing assembly is configured to be directly mounted on the chassis of the vehicle.

20. The vehicle according to claim 19, in, The vent valve is configured to have at least one vent hole formed through a surface of the battery pack housing.

21. The vehicle according to claim 19, in, The vent valve is configured to pass through the lower plate of the battery pack housing.

22. The vehicle according to claim 19, in, The exhaust valves are configured to be multiple, and the multiple exhaust valves are configured to be spaced apart from each other in the first direction.

23. The vehicle according to claim 19, in, When a thermal event occurs in the battery cell, the vent valve guides the exhaust gas downwards.

24. The vehicle according to claim 19, in, The battery pack housing has a rectangular tubular shape, and the rectangular tubular shape has an opening formed on the front or rear surface facing the first direction.

25. The vehicle according to claim 19, in, The lower plate of the battery pack housing is configured to form a step.

26. The vehicle according to claim 25, in, The lower plate is divided into a downwardly protruding edge portion, a center portion positioned above the edge portion, and a middle portion positioned between the edge portion and the center portion and positioned above the center portion.

27. The vehicle according to claim 26, in, The exhaust valve is configured to pass through the center portion of the lower plate.

28. The vehicle according to claim 19, in, The cell array also includes a module cover configured to support the battery cells.

29. The vehicle according to claim 28, in, The battery cell includes electrode leads protruding downward from the lower surface of the battery cell, and The electrode leads are not covered by the module cover.

30. The vehicle according to claim 29, in, The electrode leads and the exhaust valve are arranged adjacent to each other.

31. The vehicle according to claim 19, in, When a thermal event occurs in the battery cell, the exhaust gas is discharged downwards and configured to be discharged to the outside of the vehicle through the exhaust valve.

32. The vehicle according to claim 19, in, The battery pack housing is configured to be formed by at least one of the processes of extrusion, forging, pressing and casting.

33. The vehicle according to claim 19, in, The battery pack housings that constitute the battery pack housing assembly are configured to be welded together.

34. The vehicle according to claim 19, in, The battery pack housing is configured such that the size of the battery pack housing assembly is increased in the second direction by sequentially connecting the components.

35. The vehicle according to claim 19, in, The battery pack housing assembly is configured to be directly mounted on the chassis of the vehicle.

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