Battery cell assembly, clamp assembly for manufacturing the same, and battery pack

Abstract

According to an embodiment of the present application, a battery cell assembly includes a plurality of battery cells, and a potting unit interposed between the outside of the plurality of battery cells and the plurality of battery cells and configured to fix the plurality of battery cells. The battery cell assembly according to the present application can not include a separate case having an accommodation space for accommodating the plurality of battery cells.

Description

Technical Field

[0001] This disclosure relates to battery cell assemblies, fixture structures for manufacturing the battery cell assemblies, and battery packs. Background Technology

[0002] Unlike non-rechargeable primary batteries, secondary batteries are rechargeable and dischargeable batteries, and are used not only in portable devices, but also in electric vehicles (EVs), hybrid electric vehicles (HEVs), and other vehicles powered by electric drive sources.

[0003] Currently, widely used rechargeable batteries include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, and nickel-zinc batteries. The operating voltage of these single-cell rechargeable batteries (i.e., single-cell batteries) is approximately 2.5 V to 4.6 V. Therefore, when a higher output voltage is required, multiple battery cells are connected in series to configure a battery pack. Furthermore, depending on the required charge / discharge capacity of the battery pack, multiple battery cells can be connected in parallel to configure a battery pack. Therefore, the number of battery cells included in a battery pack can be set differently depending on the required output voltage or charge / discharge capacity.

[0004] When configuring a battery pack by connecting multiple battery cells in series or parallel, typically, a battery module, including at least one battery cell, or preferably multiple battery cells, is first configured, and then the battery pack is configured by adding other components while using at least one battery module. Here, a battery module refers to a component in which multiple battery cells are connected in series or parallel, and a battery pack refers to a component in which multiple battery modules are connected in series or parallel to increase capacity, output, etc.

[0005] However, such battery packs require a structure to secure the multiple battery modules they house. Therefore, in existing battery packs, separate components are used to secure parts such as the battery module housing, busbars, and battery management system (BMS), leading to increased material costs and weight. Summary of the Invention

[0006] Technical issues

[0007] This disclosure aims to provide a battery cell assembly having a structure in which structural elements such as busbars, BMS, and mounting elements are directly fixed to foam resin, without including a separate housing.

[0008] This disclosure also aims to improve economic efficiency by reducing the material costs of battery cell components and battery packs.

[0009] In addition, this disclosure aims to reduce the weight of battery cell assemblies and battery packs.

[0010] Furthermore, this disclosure aims to improve the energy density of battery cell components and battery packs.

[0011] Furthermore, this disclosure aims to facilitate the separation of battery cell assemblies from the fixture structure.

[0012] However, the technical problems to be solved by this disclosure are not limited to those described above, and other problems not explicitly mentioned in the following description of the invention will be apparent to those skilled in the art.

[0013] Technical solution

[0014] To achieve these objectives, exemplary embodiments of this disclosure provide a battery cell assembly comprising: a plurality of battery cells; and a potting unit inserted between the plurality of battery cells and the exterior of the plurality of battery cells, and configured to secure the plurality of battery cells. The battery cell assembly of this disclosure does not include a separate housing having a receiving space for accommodating the plurality of battery cells.

[0015] Another exemplary embodiment of this disclosure provides a battery pack including one or more battery cell assemblies.

[0016] The potting unit is exposed to the outside of the battery cell assembly.

[0017] In one aspect of this disclosure, the potting unit may include a resin or a foaming resin.

[0018] In another aspect of this disclosure, an electrical connection may be included that electrically connects multiple battery cells to each other.

[0019] Preferably, the electrical connection can be configured to be embedded in the potting unit.

[0020] In another aspect of this disclosure, a connecting member may be included, which is incorporated within the potting unit and configured to connect with another structural element.

[0021] Preferably, the connecting member can be configured as an insert nut or bushing.

[0022] In one aspect of this disclosure, a lower plate may be included, which supports the lower portion of a plurality of battery cells and the lower portion of a potting unit.

[0023] In another aspect of this disclosure, a spacer may be included, which is located above a plurality of battery cells and is configured to have an area with at least a partial opening so that at least a portion of the battery cells can be exposed to the outside.

[0024] In another aspect of this disclosure, a top frame may be included, which is disposed on the upper part of the battery cell assembly and configured to surround the outer periphery of the side surface of the battery cell assembly.

[0025] Preferably, the top frame can be configured such that at least one of the busbar and the ICB is mounted on the top frame.

[0026] Additionally, this disclosure provides a vehicle that includes at least one battery pack according to the exemplary embodiments described above.

[0027] To achieve these objectives, exemplary embodiments of this disclosure provide a clamping structure configured to house a plurality of battery cells within the clamping structure, and to insert a pad between the clamping structure and the plurality of battery cells housed within the clamping structure.

[0028] In one aspect of this disclosure, the clamp structure may include: a lower clamp configured to support a plurality of battery cells from below; a side clamp mounted on the lower clamp and configured to cover the plurality of battery cells from the side; a side pad disposed on the side clamp and configured to directly contact the plurality of battery cells; an upper clamp disposed above the plurality of battery cells and configured to connect with the side clamp; and a guide clamp detachably disposed on one side of the side clamp and including a cell receiving portion for receiving battery cells.

[0029] Preferably, the side liner may comprise silicone.

[0030] In another aspect of this disclosure, the lower clamp, the side clamp, and the upper clamp are configured to be detachably connected to each other.

[0031] Beneficial effects

[0032] The battery cell assembly according to this disclosure does not require a separate housing and allows structural elements such as busbars, BMS, and mounting elements to be directly attached to the foam resin.

[0033] Furthermore, according to this disclosure, economic efficiency can be improved by reducing the material costs of battery cell components and battery packs.

[0034] Furthermore, according to this disclosure, the weight of battery cell assemblies and battery packs can be reduced.

[0035] Furthermore, according to this disclosure, the energy density of battery cell assemblies and battery packs can be increased.

[0036] Furthermore, according to this disclosure, separation between the battery cell assembly and the clamping structure can be facilitated.

[0037] However, the effects achieved through this disclosure are not limited to those described above, and other technical effects not explicitly mentioned in the following description of the invention will be apparent to those skilled in the art. Attached Figure Description

[0038] The accompanying drawings illustrate preferred exemplary embodiments of the present disclosure and, together with the following description of the invention, are intended to provide a better understanding of the technical features of the present disclosure; therefore, the present disclosure should not be construed as limited to the drawings.

[0039] Figure 1 This is a diagram illustrating a battery cell according to an exemplary embodiment of the present disclosure.

[0040] Figure 2 This is a diagram illustrating a battery cell assembly according to an exemplary embodiment of the present disclosure.

[0041] Figure 3 This is a diagram illustrating a battery cell assembly according to another exemplary embodiment of the present disclosure.

[0042] Figure 4 This is a diagram illustrating a battery cell assembly according to yet another exemplary embodiment of the present disclosure.

[0043] Figure 5 This is a diagram illustrating a battery cell assembly according to yet another exemplary embodiment of the present disclosure.

[0044] Figure 6 This is a diagram illustrating a battery cell assembly according to yet another exemplary embodiment of the present disclosure.

[0045] Figure 7 This is a diagram illustrating a battery cell assembly according to a further exemplary embodiment of the present disclosure.

[0046] Figure 8 It is shown Figure 7 A diagram showing the completed state of the battery cell assembly.

[0047] Figure 9 This is a diagram illustrating a vehicle including a battery pack according to an exemplary embodiment of the present disclosure.

[0048] Figure 10 This is a diagram illustrating a clamp structure according to an exemplary embodiment of the present disclosure.

[0049] Figure 11 This diagram illustrates the process of connecting guide fixtures and side fixtures to manufacture battery cell assemblies.

[0050] Figure 12 It is shown Figure 11 A top view showing the structural components being connected.

[0051] Figure 13 This diagram shows the state in which the connecting member is attached to the side clamp and the side pad.

[0052] Figure 14 This diagram illustrates the process of mounting multiple battery cells in a fixture structure.

[0053] Figure 15 This diagram illustrates the process of mounting the lower plate onto multiple battery cells.

[0054] Figure 16 This diagram illustrates the process of mounting the lower fixture onto the side fixture.

[0055] Figure 17 It is shown Figure 16 The diagram shows the clamp structure in a reversed state.

[0056] Figure 18 This is a diagram illustrating a battery pack according to an exemplary embodiment of the present disclosure. Detailed Implementation

[0057] In the following detailed description, reference is made to the accompanying drawings, which form a part of this disclosure. The exemplary embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized and other changes may be made without departing from the spirit or scope of the subject matter presented herein. The advantages and features of this disclosure, as well as the methods for implementing these advantages and features, will become apparent from the exemplary embodiments described below in conjunction with the accompanying drawings. However, this disclosure is not limited to the exemplary embodiments disclosed below, but may be implemented in various different forms. The exemplary embodiments provided are merely for the purpose of completing this disclosure and to allow those skilled in the art to fully understand the scope of this disclosure. This disclosure is limited only by the scope of the claims. Therefore, in some exemplary embodiments, well-known process steps, well-known apparatus structures, and well-known techniques are not specifically described to avoid obscuring the interpretation of this disclosure. Throughout the specification, the same reference numerals denote the same elements.

[0058] In the accompanying drawings, the thickness of layers and regions is exaggerated for clarity. Throughout the specification, the same reference numerals are assigned to the same elements. When an element such as a layer, film, region, plate, etc., is referred to as "on another element," it may be "directly on the other element," or there may be intermediate elements present. Conversely, when an element is referred to as "directly on another element," it may mean that no intermediate elements are present. Furthermore, when an element such as a layer, film, region, plate, etc., is referred to as "below" another element, it may be "directly below the other element," or there may be intermediate elements present. Conversely, when an element is referred to as "directly below the other element," it may mean that no intermediate elements are present.

[0059] The expression "the two comparison targets are the same" means that they are "substantially identical." Therefore, "substantially identical" can include, for example, a deviation of 5%, which is considered low in the field. Additionally, the uniformity parameter in the predetermined region can refer to uniformity from an average perspective.

[0060] Throughout this specification, unless otherwise stated, each element may be interpreted as either singular or plural.

[0061] When a component is described as being arranged "above (or below)" or "on (or below)" another component, it should be understood that the component may be arranged to contact the upper (or lower) surface of the other component, or an additional component may be inserted between the two components.

[0062] Additionally, when a component is described as “connected,” “joined,” or “engaged” to another component, it should be understood that the components may be directly connected or joined to each other, but the components may be indirectly “connected,” “joined,” or “engaged” via additional components inserted therebetween.

[0063] Throughout this specification, unless otherwise stated, the description of “A and / or B” means A, B, or A and B, and unless otherwise stated, the description of “C to D” means C or greater and D or less.

[0064] Figure 1 This is a diagram illustrating a battery cell 10 according to an exemplary embodiment of the present disclosure.

[0065] According to an exemplary embodiment of this disclosure, the battery cell 10 is a secondary battery and can be configured as a cylindrical secondary battery, a pouch-type secondary battery, or a prismatic secondary battery. In the following, in this exemplary embodiment, it will be assumed that multiple battery cells 10 are as follows... Figure 1 The case of a cylindrical secondary battery shown will be described.

[0066] Figure 2This is a diagram illustrating a battery cell assembly 1 (or cell block) according to an exemplary embodiment of the present disclosure.

[0067] Reference Figure 2 The battery cell assembly 1 (cell block) includes a plurality of battery cells 10 and a potting unit 20 configured to fix the plurality of battery cells 10. The battery cell assembly 1 may also include an electrical connection portion 30 and / or a connecting member 40 and / or a lower plate 50 and / or a spacer 60 and / or a top frame 70.

[0068] The potting unit 20 can be disposed outside the plurality of battery cells 10 and inserted between the plurality of battery cells 10. That is, the potting unit 20 can be configured to cover both the space between the battery cells 10 and the exterior of the battery cell 10 assembly. In other words, the battery cells 10 can be configured to be embedded in the potting unit 20.

[0069] In one aspect of this disclosure, the battery cell assembly 1 may not include a separate housing having a receiving space for accommodating a plurality of battery cells 10. That is, according to the structure of this disclosure described above, since the potting unit 20 serves as a structural element for fixing and holding the battery cells 10, it is not necessary to include a separate housing or outer casing.

[0070] Therefore, the potting resin constituting the potting unit 20 can be exposed on the outer surface of the battery cell assembly 1. As an example, as shown in the figure, the battery cell assembly 1 can be formed into a right-angled parallelepiped, and the potting resin can be exposed on the six surfaces of the right-angled parallelepiped. Specifically, the potting resin can be exposed on the four outer surfaces (at least two outer surfaces) of the battery cell assembly 1, on the upper surface of the battery cell assembly 1, and on the lower surface of the battery cell assembly 1.

[0071] Multiple battery cells 10 can be fully embedded in the potting unit 20 of the battery cell assembly 1 and may not be exposed outside the potting unit 20. Alternatively, as another example, the upper or lower surface of the battery cell 10 may be exposed outside the potting unit 20.

[0072] According to the structure described in this disclosure, it eliminates the need for a separate housing and individual components, enabling a structure where structural elements such as the busbar 31, BMS, and mounting elements are directly fixed to the potting unit 20 without using a housing or separate injection-molded components. Therefore, according to this disclosure, cost reduction can be achieved by lowering the material cost of the battery cell assembly 1. For example, according to this disclosure, the cost can be reduced by approximately 20% or more compared to prior art battery cell assemblies 1. Furthermore, the weight of the battery cell assembly 1 can be reduced according to the above configuration. Additionally, the energy density of the battery cell assembly 1 can be increased according to the above configuration. Furthermore, according to this disclosure, the battery cell 10 can be effectively fixed by the potting unit 20.

[0073] In one aspect of this disclosure, the potting unit 20 may have, for example, a generally right-angled parallelepiped shape. That is, the potting unit 20 can be manufactured by infusing and curing resin (or foaming resin) while a plurality of battery cells 10 are mounted in a battery fixture having a generally right-angled parallelepiped shape. Therefore, resin can fill between the battery cells 10 to form the potting unit 20, and resin can surround the battery cells 10. Therefore, the battery cell assembly 1 does not include a separate housing, and the potting unit 20 itself can serve as the housing of the battery cell assembly 1. Therefore, there may be no housing or outer casing outside the potting unit 20 of the battery cell assembly 1.

[0074] In another aspect of this disclosure, the potting unit 20 may include resin or foaming resin.

[0075] For example, potting unit 20 may include a flame-retardant material. For example, potting unit 20 may be made of a foaming resin with a flame retardancy rating of V-0. Potting unit 20 may be made of a material having properties including heat resistance, electrical insulation, weather resistance, and water resistance. For example, potting unit 20 may include polyurethane (PU) foam. Alternatively, potting unit 20 may include a two-component resin.

[0076] Figure 3 This is a diagram illustrating a battery cell assembly 1 according to another exemplary embodiment of the present disclosure.

[0077] The potting unit 20 may include at least one recessed groove 21 formed by recessing the surface inward. For example, see reference Figure 3 An elongated groove in the shape of a rod can be provided on one side surface of the potting unit 20. However, the shape of the recessed groove 21 of this disclosure is not limited to this, and any space that can be provided on the potting unit 20 is included within the scope of the exemplary embodiments of the recessed groove 21 of this disclosure.

[0078] According to this structure, structural components such as a BMS and mounting elements that can be included in the battery cell assembly 1 can be easily installed. In other words, the recessed groove 21 can be used as a space for components that can be installed in the battery cell assembly 1.

[0079] In another aspect of this disclosure, the battery cell assembly 1 may include an electrical connection portion 30.

[0080] Reference Figure 4 The electrical connection portion 30 can be configured to electrically interconnect multiple battery cells 10. That is, the electrical connection portion 30 can be made of a conductive material. For example, the electrical connection portion 30 can include metal. More specifically, the electrical connection portion 30 can have a lead-bonded structure.

[0081] Reference Figure 4 One end of the battery cell 10 can be electrically connected to an adjacent end of the battery cell 10 via the electrical connection portion 30. That is, the battery cell assembly 1 can be configured to have a so-called cell-to-cell connection structure.

[0082] This structure allows for electrical connections between battery cells 10 without the need for separate structural components such as busbar 31. Therefore, a battery cell assembly 1 with reduced manufacturing costs and weight can be manufactured. Furthermore, based on the above configuration, various electrical connections can be achieved without being limited by the structure of the busbar 31.

[0083] In one aspect of this disclosure, the electrical connection portion 30 can be configured to be embedded in the potting unit 20. For example, after one end of the battery cell 10 and an adjacent end of the battery cell 10 are connected by the electrical connection portion 30, resin can be injected to embed the electrical connection portion 30 in the potting unit 20.

[0084] According to this structure, since the electrical connection portion 30 is not exposed to the outside and is fixed inside in a specific form, a stable electrical connection can be ensured. In particular, when the electrical connection portion 30 is a lead connection that is easily subjected to external impact, the stability of the electrical connection portion 30 can be ensured by the above structure.

[0085] Figure 4 This is a diagram illustrating a battery cell assembly 1 according to yet another exemplary embodiment of the present disclosure.

[0086] Reference Figure 4 The battery cell assembly 1 may include a connecting member 40.

[0087] The connecting member 40 can be built into the potting unit 20. That is, the connecting member 40 can be positioned embedded within the potting unit 20. One end of the connecting member 40 can be exposed outside the potting unit 20. The connecting member 40 can be configured to connect with another structural element. That is, the connecting member 40 refers to a member encompassing any connection method for connecting with another structural element. For example, the connecting member 40 can correspond to an insert nut or bushing. The connecting member 40 can be configured to be exposed on the surface of the potting unit 20. For example, as... Figure 4 As shown, the connecting member 40 can be configured to be exposed on the upper surface of the potting unit 20. Alternatively, the connecting member 40 can be disposed on the side surface and / or lower surface of the potting unit 20. Note that multiple connecting members 40 can be included in the potting unit 20. The battery cell assemblies 1 can be connected or linked to each other via the connecting members 40. Furthermore, the battery cell assemblies 1 can be secured to the battery pack housing of the battery pack 2000 via the connecting members 40.

[0088] According to this configuration, structural elements such as the busbar 31, BMS, and mounting elements can be directly attached to the potting unit 20 without using separate injection-molded components. For example, in an exemplary embodiment where the connecting member 40 is an insert nut, another structural element can be bolted to the insert nut. That is, according to this disclosure, another structural element can be easily and directly attached to the potting unit 20 without requiring a housing or separate injection-molded components.

[0089] Figure 5 This is a diagram illustrating a battery cell assembly 1 according to yet another exemplary embodiment of the present disclosure.

[0090] Reference Figure 5 The battery cell assembly 1 may include a lower plate 50.

[0091] The lower plate 50 may be located at the lower part of the battery cell assembly 1. The lower plate 50 may be configured to have a generally plate shape extending in a horizontal direction. The lower plate 50 may be configured to support the lower part of a plurality of battery cells 10 and the lower part of the potting unit 20. For example, the battery cell assembly 1 may be manufactured by attaching the battery cells 10 to the lower plate 50 with adhesive and potting resin thereon. The lower plate 50 may include a metallic material. For example, the lower plate 50 may include aluminum.

[0092] According to the above configuration, the lower plate 50 can support multiple battery cells 10, while providing a bottom surface on which resin can be poured. The lower plate 50 and the potting unit 20 can remain connected. Therefore, a more robust battery cell assembly 1 can be provided.

[0093] Figure 6This is a diagram illustrating a battery cell assembly 1 according to yet another exemplary embodiment of the present disclosure.

[0094] Reference Figure 6 The battery cell assembly 1 may include a spacer 60.

[0095] The spacer 60 can be configured to have a generally plate-like shape extending in a horizontal direction. The spacer 60 can be located above or below the plurality of battery cells 10. The spacer 60 can be configured to have at least a partially open area so that at least a portion of the battery cell 10 can be exposed to the outside.

[0096] For example, the spacer 60 may include an opening 61 formed vertically through it. In this case, one end of the battery cell 10 can be exposed through the opening 61. Note that the spacer 60 may include a groove 62 formed on its upper surface and recessed to a predetermined depth. For example, the groove 62 may be configured such that a busbar 31 is disposed thereon. The busbar 31 disposed on the groove 62 can be electrically connected to the end of the battery cell 10 exposed through the opening 61 via an electrical connection 30. That is, the electrical connection between the busbar 31 and the battery cell 10 can be achieved through the opening area of ​​the spacer 60. In this case, the electrical connection 30 may be a wire connection.

[0097] In another aspect of this disclosure, the spacer 60 can be configured to be embedded in the potting unit 20. That is, the spacer 60, the busbar 31, and the electrical connection portion 30 can be embedded in the potting unit 20.

[0098] Using this structure, a stable electrical connection between the battery cells 10 is achieved through the spacer 60. Furthermore, according to the above configuration, since the electrical connection portion 30 is not exposed to the outside and is fixed internally in a specific manner, a stable electrical connection can be ensured. In particular, when the electrical connection portion 30 is a lead connection that is susceptible to external impact, the stability of the electrical connection portion 30 can be ensured by the above structure.

[0099] Figure 7 This is a diagram illustrating a battery cell assembly according to a further exemplary embodiment of the present disclosure, and Figure 8 It is shown Figure 7 A diagram showing the completed state of battery cell assembly 1.

[0100] In one aspect of this disclosure, the battery cell assembly 1 may include a top frame 70.

[0101] Reference Figure 7 and Figure 8A top frame 70 may be disposed on the upper part of the battery cell assembly 1. The top frame 70 may be configured to surround the outer periphery of the side surface of the battery cell assembly composed of the plurality of battery cells 10. More specifically, the inner peripheral surface 71 of the top frame 70 may be configured to surround the outer periphery of the side surface of the battery cell assembly composed of the plurality of battery cells 10. For example, the inner peripheral surface 71 may be configured to have a shape complementary to the outer peripheral surface of the battery cell assembly composed of the plurality of battery cells 10.

[0102] In another aspect of this disclosure, the top frame 70 may include a mounting portion 72 capable of mounting components that may be included in the battery cell assembly 1. The top frame 70 may be configured to mount components such as busbar 31, ICB, BMS, relays, and current sensors thereon. For example, the top frame 70 may be configured to mount at least one of busbar 31 and ICB thereon.

[0103] In this configuration, at least one of the busbar 31 and the ICB can be mounted on the mounting portion 72. The mounting portion 72 can be disposed on the outer peripheral surface of the top frame 70.

[0104] According to the above configuration, other components included in the battery cell assembly 1 can be easily installed. That is, according to this disclosure, by configuring the top frame 70 to have only a minimal frame for mounting components, the weight of the battery cell assembly 1 can be reduced while achieving stable mounting of the components.

[0105] Furthermore, according to this disclosure, since the shape of the inner peripheral surface 71 of the top frame 70 matches the shape of the outer peripheral surface of the battery cell assembly composed of a plurality of battery cells 10, the fixing effect of the battery cells 10 can also be ensured.

[0106] In another aspect of this disclosure, the top frame 70 can be configured to be embedded in the potting unit 20. For example, the top frame 70 can be embedded in the potting unit 20 by attaching the top frame 70 to a plurality of battery cells 10 and then potting with resin. According to this structure, since the top frame 70 is fixed in the potting unit 20, the position of the mounting portion 72 can be consistently fixed.

[0107] Figure 18 This is a diagram illustrating a battery pack according to an exemplary embodiment of the present disclosure. As shown, the battery pack 2000 according to an exemplary embodiment of the present disclosure can accommodate at least one (or more) battery cell assemblies 1 inside the battery pack housing.

[0108] The battery pack housing may include a lower housing 2100 and a battery pack cover 2200 connected to the upper side of the lower housing 2100, and a plurality of battery cell assemblies 1 may be housed in the interior space of the lower housing 2100.

[0109] Multiple battery cell assemblies 1 exposed on the outer surface of the potting unit 20 can be secured and mounted in the lower housing 2100 of the battery pack 2000 by means of fastening members (e.g., bolts). Fastening members such as bolts can be connected to the connecting members 40 of the battery cell assembly 1 to secure the battery cell assembly 1.

[0110] Figure 9 This is a diagram illustrating a vehicle including a battery pack 2000 according to an exemplary embodiment of the present disclosure.

[0111] Reference Figure 9 The vehicle 5 according to an exemplary embodiment of the present disclosure may be, for example, an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle, and includes a battery pack 2000 according to an exemplary embodiment of the present disclosure. Examples of vehicle 5 include four-wheeled vehicles and two-wheeled vehicles. According to an exemplary embodiment of the present disclosure, vehicle 5 operates by receiving power from the battery pack 2000. Furthermore, in addition to the battery cells 10 and the battery pack 2000, vehicle 5 according to an exemplary embodiment of the present disclosure may also include various other components included in the vehicle. For example, in addition to the battery cells 10 according to an exemplary embodiment of the present disclosure, vehicle 5 according to an exemplary embodiment of the present disclosure may also include a body, a motor, control devices such as an ECU (electronic control unit), etc.

[0112] Figure 10 This is a diagram illustrating a clamp structure 100 according to an exemplary embodiment of the present disclosure.

[0113] Reference Figure 10 The fixture structure 100 can be configured to house a plurality of battery cells 10. The fixture structure 100 can be configured to insert a pad 200 between the fixture structure 100 and the plurality of battery cells 10 housed within the fixture structure 100. The fixture structure 100 can be used to manufacture a battery cell assembly 1.

[0114] According to an exemplary embodiment of this disclosure, at least one through hole may be provided on one side of the clamp structure 100. For example, at least one through hole may be provided on the upper side of the clamp structure 100. The through hole can be used as an injection port for resin injection. Note that multiple through holes may be provided. In this case, at least one of the through holes can be used as an vent hole for discharging air during resin injection.

[0115] Refer again Figure 10The clamping structure 100 may include: a lower clamp 110 configured to support a plurality of battery cells 10 from below; a side clamp 120 mounted on the lower clamp 110 and configured to cover the plurality of battery cells 10 from the side; and an upper clamp 130 disposed above the plurality of battery cells 10 and configured to connect with the side clamp 120. In this case, the upper clamp 130 may have at least one through hole.

[0116] Additionally, the fixture structure 100 may include a guide fixture 140, which is detachably disposed on one side of the side fixture 120 and includes a cell receiving portion 141 for receiving the battery cell 10. The guide fixture 140 may be configured to engage with the side fixture 120 during the manufacturing process of the battery cell assembly 1 and then be removed from the side fixture 120.

[0117] The guide clamp 140 may include a cell receiving portion 141, in which a battery cell 10 may be positioned at a specific location. For example, the cell receiving portion 141 may include a protrusion extending along the outer peripheral surface of the battery cell 10. The battery cell 10 may be mounted in the cell receiving portion 141. Note that the guide clamp 140 may include a frame receiving portion 143 on which a top frame 70 may be mounted.

[0118] Note that the clamp structure 100 may include a side pad 220 disposed on the side clamp 120. The side pad 220 may be located in the region between the side clamp 120 and the battery cell 10. The side pad 220 may be fixed to contact the inner surface of the side clamp 120. In this case, the side pad 220 may include silicone. For example, the side pad 220 may be a silicone pad and may be configured to directly contact a plurality of battery cells 10.

[0119] According to the above configuration, in the process of removing the clamping structure 100 from the battery cell assembly 1 after manufacturing the battery cell assembly 1, the clamping structure 100 and the battery cell assembly 1 can be easily separated. For example, foamed resin is not easily detached when attached to plastic or metal. Therefore, if the clamping structure 100 is composed of a side clamp 120 without side pads 220, it is not easy to remove the side clamp 120 after potting resin. However, according to the above structure of this disclosure, the potting unit 20 including foamed resin can be easily separated from the side clamp 120 by the side pads 220 including silicone.

[0120] Figures 11 to 17 It shows the use Figure 10 A diagram illustrating the process of manufacturing battery cell assembly 1 using a battery fixture.

[0121] Figure 11 This diagram illustrates the process of connecting the guide jig 140 and the side jig 120 to manufacture the battery cell assembly 1. (Refer to...) Figure 11 The top frame 70 and the side clamp 120 are mounted on the guide clamp 140, which includes the cell receiving portion 141 and the frame receiving portion 143. In this case, the side pad 220 is attached to the inner surface of the side clamp 120. The side pad 220 may include silicone as described above.

[0122] Figure 12 It is shown Figure 11 A top view showing the structural components connected. (Refer to...) Figure 12 Adhesive can be applied to the top frame 70 to secure the battery cell 10 and the top frame 70. For example, as... Figure 12 As shown, glue can be applied along the main body of the top frame 70.

[0123] Figure 13 This diagram shows the connection member 40 attached to the side clamp 120 and the side pad 220. In order to embed the connection member 40 into the potting unit 20, the connection member 40 needs to be fixed in a predetermined position before potting. At this time, as... Figure 13 As shown, the connecting member 40 can also be pre-attached to the side clamp 120. Afterwards, when the potting resin is poured and cured, and then the side clamp 120 is removed, the connecting member 40 can be removed together with the side clamp 120, and then only the connecting member 40 can be reinserted into the potting unit 20, thereby fixing the connecting member 40 at a predetermined position on the potting unit 20. Alternatively, as... Figure 13 As shown, the following method is also possible, wherein, with the connecting member 40 pre-attached to the side clamp 120, potting resin is poured and cured, and then, with the connecting member 40 attached to the potting unit 20, the side clamp 120 is selectively removed only. Alternatively, although not shown, but as another exemplary embodiment, the following method is also possible, wherein the connecting member 40 is fixed to the side gasket 220 by a pin, and then potting resin is poured and cured.

[0124] Figure 14 This is a diagram illustrating the process of mounting multiple battery cells 10 in a fixture structure 100.

[0125] Reference Figure 14 A cell receiving portion 141 capable of accommodating the battery cell 10 can be provided on the guide clamp 140. Preferably, multiple cell receiving portions 141 are provided. The spaces between the cell receiving portions 141 can be separated by physical components. Therefore, when the battery cell 10 is placed in the cell receiving portion 141, movement to other locations can be restricted.

[0126] In this case, refer to Figure 14 The battery cell 10 can be installed with its upper surface facing downwards. That is, referring to... Figure 14 The surface of the battery cell 10 visible in the upwardly open clamping structure 100 can correspond to the lower surface of the battery cell 10. This is because the clamping structure 100 will be reversed at a later stage, so that the battery cell 10 is mounted with its upper surface facing down.

[0127] Figure 15 This diagram illustrates the process of mounting the lower plate 50 onto multiple battery cells 10.

[0128] Once multiple battery cells 10 are mounted on the guide clamp 140, adhesive is applied to one surface of each battery cell 10. For example, as described above... Figure 14 Referring to the accompanying drawings, the lower surface of the battery cell 10 faces upwards. At this time, adhesive can be applied to the lower surface of the battery cell 10. The lower plate 50 can adhere to the surface to which adhesive has been applied. That is, the lower surface of the battery cell 10 and the lower plate 50 can adhere to each other. When the clamping structure 100 is reversed in a later stage, the lower plate 50 is used to support multiple battery cells 10 from below.

[0129] Figure 16 This is a diagram showing the process of mounting the lower clamp 110 onto the side clamp 120.

[0130] like Figure 15 As shown, after the lower plate 50 is bonded to the lower surface of the battery cell 10, the lower clamp 110 can be connected to the side clamp 120 to provide pressure to the bonding surface. The lower clamp 110 can be configured to support the lower plate 50 from one side. The lower clamp 110 and the side clamp 120 can be connected by, for example, a bolted connection. However, the connection method of the lower clamp 110 and the side clamp 120 is not limited to this, and any detachable connection method is included within the scope of this disclosure.

[0131] Figure 17 It is shown Figure 16 The diagram shows the state of the clamp structure 100 being reversed vertically.

[0132] When the lower clamp 110 is connected to Figure 16 When the side clamp 120 is in place, the clamp structure 100 is reversed vertically. After the clamp structure 100 is reversed vertically, the adhesive is cured at a predetermined temperature for a predetermined time. For example, the adhesive can be cured at approximately 55°C to 60°C for approximately 50 minutes to 1 hour.

[0133] Note that when the clamp structure 100 is reversed, the guide clamp 140 located at the lower part becomes located at the upper part of the clamp structure 100. Then, the guide clamp 140 is removed from the side clamp 120. The guide clamp 140 is a component used to guide the position of the battery cell 10 and / or the top frame 70. Since the positions of the top frame 70 and the battery cell 10 are fixed by adhesive or the like, the positions of the battery cell 10 and the top frame 70 can be fixed even when the guide clamp 140 is removed.

[0134] When the guide clamp 140 is removed, the following is achieved: Figure 17 The battery cell 10 is shown in the configuration where the upper surface of the battery cell 10 and a portion of the top frame 70 are exposed upwards. In this configuration, electrical connections 30 can be formed between the battery cells 10. For example, the battery cell 10 and adjacent battery cells 10 can be electrically connected by wire bonding. Various series and parallel connection methods can be implemented by wire bonding.

[0135] Subsequently, potting resin can be injected between the battery cells 10 to form a potting unit 20. At this time, the potting unit 20 can be configured to bury the electrical connection portion 30.

[0136] In one aspect of this disclosure, a predetermined space is preferably provided between the gasket 200 and the battery cell 10, such that the gasket 200 and the battery cell 10 do not directly contact each other. That is, it is necessary to ensure that the space between the gasket 200 and the battery cell 10 allows potting resin to be injected into that space.

[0137] After pouring and encapsulating resin as described above, when... Figure 10 As shown, when the upper clamp 130 is connected to the side clamp 120 and cured at room temperature, the resin is cured and forms the potting unit 20. Subsequently, when the clamp structure 100 is disassembled, as... Figure 8 The battery cell assembly 1 shown is now complete.

[0138] Alternatively, as another exemplary implementation, with Figure 10 Unlike the side clamps 120, the upper clamp 130 may include at least one through hole through which resin can be injected after the upper clamp 130 is connected to the side clamp 120. After the resin cures, any excess resin is removed, and then the clamp structure 100 is disassembled.

[0139] The clamp structure 100 can be configured such that the lower clamp 110, the side clamp 120, and the upper clamp 130 can all be detached from each other. That is, the lower clamp 110, the side clamp 120, and the upper clamp 130 can be configured to be detachably connected to each other.

[0140] According to the clamping structure 100 of this disclosure as described above, since the battery cell assembly 1 does not include a separate housing and the battery cell 10 is fixed and housed by the potting unit 20, material costs and weight can be reduced. Therefore, the energy density of the battery cell assembly 1 and the battery pack 2000 can be increased. Furthermore, since the clamping structure 100 used to manufacture this battery cell assembly 1 includes a material in the area in contact with the potting unit 20 that is easily separable from the potting unit 20, the process of disassembling the clamping structure 100 can be performed smoothly.

[0141] Note that although this document uses terms such as up and down to indicate direction, these terms are used for convenience of description only, and it will be apparent to those skilled in the art that these terms may vary depending on the location of the target object or the observer's position.

[0142] Although this disclosure has been described with reference to limited exemplary embodiments and accompanying drawings, this disclosure is not limited thereto, and various modifications and variations can be made by those skilled in the art to which this disclosure pertains within the technical spirit of this disclosure and the equivalents of the described claims.

[0143] Industrial applicability

[0144] This disclosure may provide a battery cell assembly that does not require a separate housing and allows structural elements such as busbars, BMS, and mounting elements to be directly attached to the foam resin.

Claims

1. A battery cell assembly, the battery cell assembly comprising: Multiple battery cells; as well as A potting unit is inserted between the plurality of battery cells and the outside of the plurality of battery cells and is configured to fix the plurality of battery cells.

2. The battery cell assembly according to claim 1, wherein, The battery cell assembly does not include a separate housing having a receiving space for accommodating the plurality of battery cells.

3. The battery cell assembly according to claim 1, wherein, The potting unit is exposed to the outside of the battery cell assembly.

4. The battery cell assembly according to claim 1, wherein, The potting unit includes resin.

5. The battery cell assembly according to claim 1, wherein, The potting unit includes foaming resin.

6. The battery cell assembly according to claim 1, wherein the battery cell assembly further comprises an electrical connection portion, the electrical connection portion electrically connecting the plurality of battery cells to each other.

7. The battery cell assembly according to claim 6, wherein, The electrical connection is configured to be embedded in the potting unit.

8. The battery cell assembly of claim 1, further comprising a coupling member, the coupling member being incorporated within the potting unit and configured to be coupled to another structural element.

9. The battery cell assembly according to claim 8, wherein, The connecting member is configured as an insert nut or bushing.

10. The battery cell assembly according to claim 1, wherein the battery cell assembly further comprises a lower plate, the lower plate supporting the lower part of the plurality of battery cells and the lower part of the potting unit.

11. The battery cell assembly of claim 1, further comprising a spacer located above the plurality of battery cells and configured to have at least a partially open area so that at least a portion of the battery cells can be exposed to the outside.

12. The battery cell assembly of claim 1, further comprising a top frame disposed on the upper part of the battery cell assembly and configured to surround the outer periphery of the side surface of the battery cell assembly.

13. The battery cell assembly according to claim 12, wherein, The top frame is configured such that at least one of the busbar and the ICB is mounted on the top frame.

14. A battery pack comprising one or more battery cell assemblies according to any one of claims 1 to 13.

15. A vehicle comprising the battery pack according to claim 14.

16. A clamping structure configured to accommodate a plurality of battery cells within the clamping structure, and The clamping structure is configured to insert a pad between the clamping structure and the plurality of battery cells housed within the clamping structure.

17. The clamping structure according to claim 16, wherein the clamping structure comprises: A lower clamp, configured to support the plurality of battery cells from below; A side clamp is mounted on the lower clamp and configured to cover the plurality of battery cells from the side; Side pads, the side pads being disposed on the side clamps; An upper clamp is disposed above the plurality of battery cells and configured to be connected to the side clamp; as well as A guide clamp is detachably disposed on one side of the side clamp and includes a cell receiving portion for accommodating the battery cell.

18. The clamp structure according to claim 17, wherein, The side liner is made of silicone.

19. The clamp structure according to claim 17, wherein, The lower clamp, the side clamp, and the upper clamp are configured to be detachably connected to each other.

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