Battery cell assembly and battery pack including same

Abstract

The battery pack includes a housing, a battery assembly, and a first cover. The housing includes an opening and a first surface facing the opening. The battery assembly is accommodated in the housing. The first cover covers the opening and is coupled to the housing. A first side of the battery assembly is coupled to a first side of the first cover. A second side of the battery assembly is spaced apart from the first surface of the housing.

Description

[Technical Field]

[0001] The present invention relates to battery packs, and more particularly to battery packs that include one or more battery assemblies.

[0002] This application claims the benefit of priority to Korean Patent Application No. 10-2023-0082724, filed in Korea on June 27, 2023, and all contents disclosed in the documents of this Korean patent application are incorporated herein by reference. [Background technology]

[0003] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. Secondary batteries are widely used as energy sources for a variety of wireless devices, such as handsets, laptops, and wireless vacuum cleaners. In recent years, improvements in energy density and economies of scale have dramatically reduced the manufacturing cost per unit capacity of secondary batteries. As the driving range of battery electric vehicles (BEVs) has increased to the same level as fuel-powered vehicles, the primary use of secondary batteries has shifted from mobile devices to mobility.

[0004] As secondary batteries are used in mobility, there is a growing demand for their safety. Research into technologies to improve the safety of secondary batteries is essential, as a fire or other accident involving a secondary battery used in mobility could put the driver's life at risk.

[0005] If a thermal runaway event occurs inside the battery pack, gas and flames will head toward the passenger compartment, making it difficult to ensure passenger safety. In addition, high-temperature gas and flames will concentrate on the top plate of the battery pack, making it easy for the thermal runaway event to spread to adjacent modules and battery cells.

[0006] Furthermore, since the battery assembly is tightly supported on the base plate at the bottom of the vehicle, if an impact occurs to the bottom of the vehicle when driving on hard ground such as unpaved roads, the battery assembly may be damaged.

[0007] The background discussion provided herein is intended to generally present the context of the present disclosure. Unless otherwise expressly stated herein, the material described in this section is not prior art to the claims of this application and is not admitted as prior art or an admission of prior art by inclusion in this section. Summary of the Invention [Problem to be solved by the invention]

[0008] The problem to be solved by the technical idea of ​​the present disclosure is to provide a battery pack with improved safety.

[0009] These and other objects and advantages of the present disclosure can be understood from the following detailed description and will become more fully apparent from exemplary embodiments of the present disclosure, and it will be readily apparent that the objects and advantages of the present disclosure can be realized by the means and combinations thereof set forth in the appended claims. [Means for solving the problem]

[0010] In order to solve the above-mentioned problems, according to an exemplary embodiment of the present disclosure, a battery pack is provided.

[0011] In one embodiment, the battery pack includes a housing including an opening and a first surface facing the opening, a battery assembly accommodated in the housing, and a first cover covering the opening and coupled to the housing. A first side of the battery assembly can be coupled to a first side of the first cover, and a second side of the battery assembly can be spaced apart from the first surface of the housing.

[0012] In another aspect, the battery pack may include one or more of the following features. A first side of the battery assembly may be attached to a first side of the first cover. The battery pack may further include a first layer between the battery assembly and the first cover. The first cover may include a cooling channel between a first side and a second side of the first cover. The first side of the first cover may face a second side of the first cover. The battery assembly may be fastened to the first cover and / or the housing. The housing may further include a sidewall coupled to a first edge of a first surface. The housing may include a mounting portion on the sidewall. The battery assembly may be coupled to the mounting portion. The first cover may be coupled to the mounting portion. The housing may further include an exhaust portion. The housing may further include a battery support structure on the first surface. The battery assembly may be coupled to the battery support structure. The battery assembly may further include a cell assembly including battery cells and a bus bar coupled to a first side of the cell assembly. The battery assembly may further include a second cover. The second cover may be coupled to a second side of the cell assembly. The battery pack may further include a first layer. The first layer may include a thermal interface material (TIM). The thermal interface material may include a thermal resin, and the first layer may be located on a surface of the second cover. The battery assembly may further include a third cover coupled to a third side of the cell assembly, and a cooling portion located on at least one of the second cover or the third cover. The battery assembly may further include a second cover coupled to the second side of the cell assembly, and a third cover coupled to the third side of the cell assembly.The second cover may have a first shape, and the third cover may have a second shape. The first shape and the second shape may be configured to couple with each other. The battery assembly may include a first cell assembly and a second cell assembly. The first cell assembly may include a first bus bar, and the second cell assembly may include a second bus bar. The first cell assembly may be coupled to the second cell assembly via the first bus bar and the second bus bar. The battery assembly may further include a bus bar frame including the bus bars.

[0013] In another embodiment, a vehicle may include a battery pack and a frame. The battery pack may include a housing including an opening and a surface facing the opening, a cover configured to cover the opening, and a battery assembly coupled to the cover and spaced apart from the surface. The battery pack may be housed within the frame. A vehicle interior may be located above at least a first portion of the battery pack. The frame may be located below at least a second portion of the battery pack.

[0014] In another embodiment, a battery assembly may include a cell assembly including battery cells, a first cover coupled to a first side of the cell assembly, a second cover coupled to a second side of the cell assembly, and a layer interposed between the second cover and the second side of the cell assembly. The first cover may include a first cooling portion. The second cover may include a second cooling portion. The first cooling portion may include a venting opening. The second cooling portion may include a cooling channel.

[0015] In another embodiment, a battery pack may include a battery assembly including a plurality of battery cells, and a pack housing that houses the battery assembly, wherein the pack housing includes a top plate on which an upper surface of the battery assembly is supported in a suspended state, and a bottom plate opposite the top plate, and includes a lower pack housing coupled to the top plate, and a free volume may be provided between the lower surface of the battery assembly and the bottom plate.

[0016] An upper surface of the battery assembly and a lower surface of the top plate may be tightly coupled to each other.

[0017] A TIM (Thermal Interface Material) layer including a thermal resin may be further included between the battery assembly and the top plate, and the battery assembly may be tightly bonded to and supported on the lower surface of the top plate by the TIM layer.

[0018] The top plate may include a plurality of cooling channels.

[0019] In addition, the battery assembly may be fastened to the top plate and / or the lower pack housing.

[0020] The lower pack housing may include a side wall that is coupled to and surrounds the bottom plate, and an assembly mounting portion may be provided on the side wall to support a side surface of the battery assembly that is perpendicular to an upper surface of the battery assembly.

[0021] The top plate may be mounted on an upper surface of the assembly mounting portion.

[0022] The lower pack housing may include an exhaust system.

[0023] According to an exemplary embodiment, a battery support may be provided on the bottom plate, and the battery assembly may be supported by the battery support so as to be spaced apart from an upper surface of the bottom plate.

[0024] The battery assembly is a battery cell assembly including a plurality of battery cells; The battery cell assembly may include a plurality of bus bars coupled to at least one side of the battery cell assembly, or a bus bar frame including the plurality of bus bars.

[0025] The battery assembly may further include a module case that houses the battery cell assembly.

[0026] A TIM layer including a thermal resin may be included on an inner surface of the module case in contact with at least one of the upper and lower surfaces of the battery cell assembly.

[0027] A cooling device may be provided in at least one of an upper case in contact with an upper surface of the battery cell assembly and a lower case in contact with a lower surface of the battery cell assembly in the module case.

[0028] The battery assembly may include a first side plate coupled to a first side of the battery cell assembly and a second side plate coupled to a second side of the battery cell assembly.

[0029] The first and second side plates may have complementary interlocking structures.

[0030] The battery assembly may include a plurality of battery cell assemblies connected along a longitudinal direction of the battery assembly.

[0031] As another aspect of the present disclosure, an electric vehicle can be provided that includes the above-described exemplary battery pack and a body frame to which the battery pack is attached, in which a vehicle interior is disposed on the top plate side of the battery pack and the body frame is disposed on the bottom plate side of the battery pack. [Effects of the Invention]

[0032] In a battery pack according to an exemplary embodiment of the present disclosure, a battery assembly is supported in a suspended state on a top plate located on the passenger compartment side of a vehicle, and a free volume is provided between the lower surface of the battery assembly and a bottom plate of the battery pack located at the bottom of the vehicle.

[0033] This allows the high-temperature gas generated from the battery assembly to move to the free volume even if a thermal runaway event occurs, thereby protecting passengers in the vehicle cabin.

[0034] In addition, even if an impact is applied to the bottom plate side of the battery pack from the bottom of the vehicle, the free volume separates the battery assembly from the bottom plate, thereby effectively protecting structures within the battery pack, such as the battery assembly.

[0035] The effects that can be obtained from the exemplary embodiments of the present disclosure are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood by a person having ordinary skill in the art to which the exemplary embodiments of the present disclosure belong from the following description. That is, unintended effects accompanying the implementation of the exemplary embodiments of the present disclosure can also be derived by a person having ordinary skill in the art from the exemplary embodiments of the present disclosure. The following drawings attached to this specification illustrate preferred embodiments of the present invention and, together with the detailed description of the invention described below, serve to further understand the technical concept of the present invention. Therefore, the present invention should not be interpreted as being limited only to the matters shown in such drawings. [Brief explanation of the drawings]

[0036] [Figure 1] FIG. 2 is a cross-sectional view of the battery pack. [Figure 2] FIG. 2 is a cross-sectional view of the battery pack. [Figure 3] FIG. 1 is a cross-sectional view of a battery pack according to an exemplary embodiment of the present disclosure. [Figure 4] FIG. 1 is a cross-sectional view of a battery pack according to an exemplary embodiment of the present disclosure. [Figure 5] FIG. 1 is a cross-sectional view of a battery pack according to an exemplary embodiment of the present disclosure. [Figure 6] FIG. 1 is a perspective view of an exemplary embodiment of a battery assembly housed within a battery pack. [Figure 7] FIG. 1 is a perspective view of an exemplary embodiment of a battery assembly. [Figure 8] FIG. 10 is a perspective view of another exemplary embodiment of a battery assembly. [Figure 9] FIG. 10 is a perspective view of another exemplary embodiment of a battery assembly. [Figure 10] FIG. 10 is a perspective view showing the coupling relationship of the battery assembly of FIG. 9. [Figure 11] FIG. 10 is an exploded perspective view of another exemplary embodiment of a battery assembly. [Figure 12] 12 is a perspective view showing the bottom plate of the lower case of the battery assembly of FIG. 11. FIG. [Figure 13] FIG. 12 is a perspective view of the battery assembly of FIG. 11 as seen from the top side. [Figure 14] FIG. 12 is a perspective view of the battery assembly of FIG. 11 as viewed from the bottom side. [Figure 15] FIG. 10 is a cross-sectional view of a battery pack according to another exemplary embodiment of the present disclosure. [Figure 16] FIG. 10 is a cross-sectional view of a battery pack according to another exemplary embodiment of the present disclosure. [Figure 17]FIG. 10 is a perspective view of another exemplary embodiment of a battery assembly. [Figure 18] 1 is a schematic diagram showing the structure of an electric vehicle equipped with a battery pack according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0037] Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Before that, the terms and words used in the specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, but should be interpreted as meanings and concepts that are consistent with the technical idea of ​​the present invention based on the principle that an inventor can appropriately define the concepts of terms to best describe his own invention.

[0038] Therefore, the embodiments described in this specification and the configurations shown in the drawings are merely the most preferred embodiments of the present disclosure and do not represent the entire technical idea of ​​the present disclosure, and there may be various equivalents and modifications that can replace them at the time of filing this application.

[0039] Furthermore, in the description of the present disclosure, if it is determined that a specific description of related publicly known configurations or functions may obscure the gist of the present disclosure, such detailed description will be omitted.

[0040] The embodiments of the present disclosure are provided to more completely explain the present disclosure to those skilled in the art, and therefore the shapes and sizes of components in the drawings may be exaggerated, omitted, or illustrated schematically for clearer explanation. Therefore, the sizes and proportions of each component do not completely reflect the actual sizes and proportions.

[0041] The subject matter claimed herein may be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, certain exemplary embodiments. Any embodiment or implementation described herein as "exemplary" should not be construed as preferred or advantageous over other embodiments or implementations, but is intended to reflect or indicate that the embodiment is an "exemplary" embodiment. Because claimed subject matter can be embodied in a variety of forms, claimed subject matter should not be construed as limited to any exemplary embodiment described herein. The exemplary embodiments are provided merely for illustrative purposes. Likewise, a reasonably broad scope is intended for the subject matter claimed or covered in the claims.

[0042] Throughout the specification and claims, terms may have meanings suggested or implied by context beyond those explicitly stated. Similarly, the phrase "in one embodiment" as used herein does not necessarily refer to the same embodiment, and the phrase "in another embodiment" as used herein does not necessarily refer to other embodiments. For example, claimed subject matter is intended to include combinations of example embodiments, in whole or in part.

[0043] The terms used below can be interpreted in the broadest reasonable manner, even when used in conjunction with the detailed description of specific examples of the present disclosure. Of course, certain terms can be defined below, but any terms intended to be interpreted in a restrictive manner will be clearly and specifically defined in the detailed description. The general description above and the detailed description below are merely exemplary and explanatory and do not limit the claimed features.

[0044] In this disclosure, the term "based on" means "based at least in part on." Ordinal terms such as "first" and "second" may be used to distinguish one component from another among various components, but are not intended to limit the components to that term. The singular includes the plural unless the context clearly dictates otherwise. The term "exemplary" is used to mean "an example of" rather than "ideal." The term "or" is inclusive and refers to some or all of the listed items. The terms "comprise," "including," "having," "having," or variations thereof may be intended to encompass a non-exclusive inclusion, such that a process, method, or article that includes the listed components does not necessarily include the listed components, but may include other components not expressly listed or inherent in the process, method, article, or device. Relative terms such as "substantially" and "generally" are used to indicate a possible variation of ±5% from the stated or understood value.

[0045] Furthermore, throughout the specification, when a component is referred to as being "connected" or "coupled" to another component, it is not limited to being "directly connected" or "directly coupled," but also includes being "indirectly connected" or "indirectly coupled" with one or more components disposed therebetween.

[0046] 1 and 2 are cross-sectional views of a battery pack 10. FIG.

[0047] As shown in the figure, a conventional battery pack 10 has a battery assembly 1, such as a battery module, mounted on a lower pack housing 2 having a base plate 2b (bottom plate). A top plate (pack cover) 2a is mounted on the upper part of the lower pack housing 2, covering the battery module. When the battery pack 10 is mounted on a vehicle, the vehicle interior is located above the top plate 2a. In addition, a vehicle frame is located below the base plate 2b, and the battery pack 10 is mounted on the vehicle frame.

[0048] 3 and 4 are cross-sectional views illustrating a battery pack according to an exemplary embodiment of the present disclosure.

[0049] The battery pack 100 of this embodiment includes a battery assembly 110 and a pack housing 120 .

[0050] 3 and 4, the X direction indicates the longitudinal direction of the battery assembly 110. The Y direction indicates the width direction of the battery assembly. The Z direction indicates the height direction of the battery pack. The ZT direction is the direction toward the top (TOP) of the Z direction, and the ZB direction is the opposite direction to the ZT direction. The battery assembly 110 may be, but is not limited to, one of the battery assemblies disclosed in FIGS. 6(a) to 14 according to embodiments of the present disclosure.

[0051] For clarity of explanation and illustration, the battery assembly 110 will be described with reference to the battery assembly 110A shown in Figure 6(a). Accordingly, the battery assemblies 110 and 110A will be referred to interchangeably with reference to Figure 6(a). However, the battery assembly 110 of the present disclosure is not limited to the battery assembly 110A.

[0052] Referring to FIG. 6(a), a battery assembly 110A can include a plurality of battery cells 111a.

[0053] The plurality of battery cells 111a may be basic units of a lithium ion battery, e.g., a secondary battery. Each of the plurality of battery cells 111a may include an electrode assembly, an electrolyte, and a case. The plurality of battery cells 111a may be classified as a lithium ion battery, a lithium ion polymer battery, a lithium polymer battery, or the like depending on the configuration of the electrode assembly and the electrolyte. Lithium ion polymer batteries are less likely to leak electrolyte, are easier to manufacture, and have a higher occupancy rate within a secondary battery.

[0054] Each of the plurality of battery cells 111a may be any one of a cylindrical battery cell, a prismatic battery cell, and a pouch-type battery cell, but is not limited thereto. The electrode assembly of a cylindrical battery cell may be arranged or housed in a cylindrical metal can. The electrode assembly of a prismatic battery cell may be arranged or housed in a prismatic metal can. However, other suitable shapes, sizes, and / or materials may be used for the can. The electrode assembly of a pouch-type battery cell may be arranged or housed in a pouch case including an aluminum laminate sheet.

[0055] The electrode assembly arranged or housed in the battery case may include a positive electrode, a negative electrode, and a separator interposed between the positive and negative electrodes. Electrode assemblies may be classified into a jelly roll type or a stack type depending on their pattern or shape. A jelly roll type may be a rolled-up electrode, a negative electrode, and a separator interposed therebetween. A stack type may include multiple positive electrodes, multiple negative electrodes, and multiple separators interposed therebetween, stacked in sequence.

[0056] According to an exemplary embodiment, the plurality of battery cells 111a may be connected in series and / or parallel. As an example, the plurality of battery cells 111a may be connected in series with each other. Alternatively, the plurality of battery cells 111a may be connected in parallel with each other. Additionally or alternatively, the plurality of battery cells 111a connected in parallel with each other may form a group, and the group of the plurality of battery cells 111a may be connected in series.

[0057] The plurality of battery cells 111a may be grouped together to obtain a necessary or desired electrical capacity. For example, a plurality of prismatic battery cells or pouch-type battery cells may be stacked to form a battery cell assembly having a cell stack form. A plurality of cylindrical battery cells may be inserted into a plurality of insertion holes of a support frame installed in a module case to form a battery cell assembly.

[0058] In some embodiments, the battery cell assembly 111 may include a compression pad or the like between the battery cells 111 a to prevent swelling. Alternatively, a thermal barrier may be provided between the battery cells 111 a. For example, the thermal barrier may include a flame-retardant material such as ceramic or a coated glass material.

[0059] The battery assembly 110A may further include a bus bar (e.g., B) for electrically connecting the plurality of battery cells 111a to each other. The bus bar may be an inter-bus bar connected to each battery cell to electrically connect the battery cells 111a, or a terminal bus bar for electrically connecting the battery assembly to an external electric device.

[0060] The bus bars may be attached to a bus bar frame. For example, a bus bar frame BFA may be provided on at least one side of the battery cell assembly 111. A bus bar frame BFA may be provided on one side of the battery cell assembly 111 (e.g., a battery cell stack) of a pouch-type battery cell. In the case of a battery cell assembly including pouch-type battery cells from which electrode leads are led out in a single direction, a bus bar frame may be provided on one side of the stack from which the electrode leads are led out. In the case of a battery cell assembly including pouch-type battery cells from which electrode leads are led out in multiple directions (e.g., two directions), a bus bar frame may be provided on both sides (e.g., front and rear) of the stack from which the electrode leads are led out.

[0061] Alternatively, in the case of a prismatic battery cell, since the electrode lead portion is usually led out from one surface (for example, the top surface) of the laminate, a bus bar frame can be provided on that one surface side.

[0062] In the case of a cylindrical battery cell, a bus bar may be provided on a side of the battery cell assembly from which an electrode terminal can be led out, and in this case, each bus bar may be installed on a structure such as a bus bar frame.

[0063] An end plate 114 may be provided to cover the bus bar frame BFA or to cover at least one side of the battery cell assembly. For example, in the case of a pouch-type battery cell stack, end plates 114, 115 may be provided to cover the bus bar frame BFA.

[0064] In the case of a rectangular battery cell, end plates may be installed at the front and rear ends of the battery cells in the stacking direction, but the present invention is not limited thereto.

[0065] According to an exemplary embodiment, the battery assembly 110 may further include a housing or case that accommodates the above-mentioned battery cell assembly 111 and the bus bar frame BFA.

[0066] For example, the case may be a module case 112, 113, and the battery assembly 110 may be a battery module.

[0067] As shown in FIG. 6(a), the battery assembly 110 may have a configuration in which at least a portion of a module case 112, 113 surrounding the top, bottom, left and right sides of a plurality of battery cells or a battery cell assembly 111 includes an opening on a side where a bus bar frame BFA is provided.

[0068] In some embodiments, the battery pack of the present disclosure may not include a module case 112, 113 that surrounds the battery cell or battery cell assembly 111 from above, below, left, and right.

[0069] Alternatively, a housing or case may be provided that covers only a portion of the top, bottom, left, or right sides of the battery cell or battery cell assembly 111. For example, side plates may be provided that cover both the left and right sides of the battery cell or battery cell assembly 111. In this case, the top and / or bottom of the battery cell or battery cell assembly 111 may be open or exposed.

[0070] 3 again, the pack housing 120 may include a space for accommodating the battery assembly 110. The pack housing 120 may include a lower pack housing 120B having a bottom plate 121 (e.g., the bottom or bottom wall of the lower pack housing 120B as shown in FIG. 3), and a top plate 120A (or a cover or lid) that covers and is coupled to the lower pack housing 120B.

[0071] As shown in FIG. 3, the bottom plate 121 may form the bottom or bottom surface of the battery pack and may be supported by a vehicle frame when the battery pack 100 is mounted on a vehicle. Side walls 122 and 123 may be provided around the bottom plate 121. In FIGS. 3 and 4, side walls 122 and 123 are shown on both sides of the bottom plate 121. However, side walls may also be provided on the front and rear surfaces of the bottom plate 121. For ease of explanation and illustration, the front and rear side walls are not shown in FIGS. 3 and 4. The bottom plate 121 and the front, rear, and both side walls may form a lower pack housing 120B. The bottom plate 121 and the side walls may be joined to each other by a method such as, but not limited to, friction stir welding. In this specification, terms such as front, rear, left, and right are used to describe the position, location, and / or orientation of various components of battery pack 100, and the various components may be referred to using ordinal numbers such as "first" and "second" to distinguish their position, location, and / or orientation, but are not limited to the positions, location, and / or orientations described above.

[0072] A top plate 120A may be coupled to an upper portion of the lower pack housing 120B. That is, the top plate 120A may be a pack lid that covers the lower pack housing 120B and the battery assembly 110.

[0073] The vehicle cabin may be located above the top plate 120A.

[0074] The upper surface of the battery assembly 110 may be supported in a suspended state by the top plate 120A, or the upper surface of the battery assembly 110 may be attached or fixed to the top plate 120A. That is, the battery assembly 110 may be coupled to the lower surface of the top plate 120A. A free volume FV is provided between the lower surface of the battery assembly 110 and the bottom plate 121. That is, as shown in FIG. 3, a space provided between an exposed portion of the battery assembly 110 facing the top plate 120A and the bottom plate 121 may be defined as the free volume FV. For example, the battery assembly 110 may be spaced apart from the surface of the bottom plate 121. In some embodiments, the distance between the bottom plate 121 and the battery assembly 110 may be selected from the ranges of 5 mm to 30 mm, 8 mm to 20 mm, or 10 mm to 16 mm, but is not limited thereto.

[0075] If the bottom plate is thick or has high rigidity, the bottom plate height can be reduced.

[0076] Therefore, the battery pack 100 of the present disclosure has a support structure in which the battery assembly 110 is supported in a suspended state on the top plate 120A. In addition, a free volume FV may be provided between the bottom of the battery pack (bottom plate 121) and the battery assembly 110. This allows gas and flames generated in, for example, a thermal runaway situation to move to the free volume FV, communicate with the free volume FV, or move through the free volume FV. In other words, the free volume FV serves as a venting passage through which high-temperature gas and flames can move.

[0077] In addition, even when a strong impact occurs due to foreign objects flying under the vehicle while driving on a hard surface such as an unpaved road, the free volume FV can absorb the impact. Therefore, the battery assembly 110 can be prevented from being damaged by the impact. The free volume FV can be defined as the space between the lower surface of the battery assembly 110 and the inner surface of the bottom plate 121. For example, even when the bottom plate 121 deforms toward the battery assembly 110 due to an external impact from below, the free volume FV can accommodate the deformation to some extent within the space. In one embodiment, the free volume FV may not include other structural components. Alternatively, a structure that supports the battery assembly 110 may be partially installed on the free volume FV. In one embodiment, even when a structure is installed in the free volume FV, a volume or distance sufficient to accommodate the deformation of the bottom plate 121 may be provided between the battery assembly 110 and the bottom plate 121.

[0078] In one embodiment, the height of the free volume FV, i.e., the length or distance between the bottom plate 121 and the battery assembly 110, is preferably sufficient to absorb the impact. The height of the free volume FV may vary depending on the measurement position of the bottom plate 112. For example, as shown in FIG. 3, the height or distance of the free volume FV between the mounting portion 122a or 123a and the inner surface of the bottom plate 112 may be greater than the distance between the bottom surface of the battery assembly 110 and the inner surface of the bottom plate 112, but the range of the height or distance of the free volume FV is not limited thereto. In some embodiments, the distance between the bottom plate 121 and the battery assembly 110 may be selected from the ranges of 5 mm to 30 mm, 8 mm to 20 mm, or 10 mm to 16 mm, but is not limited thereto.

[0079] The height of the free volume FV may be determined based on the thickness and rigidity of the vehicle frame or the bottom plate 121, the specifications and size of the battery pack, the amount of gas generated and the rate of gas discharge during thermal runaway, etc. For example, if the vehicle frame or the bottom plate 121 is thick or rigid, the size and height of the free volume FV may be relatively reduced. If the thickness or rigidity is low, the bottom plate 121 is likely to deform, and therefore the height of the free volume FV needs to be increased to protect the battery assembly 110. In some embodiments, the thickness of the bottom plate 121 may be selected from the range of 1 mm to 5 mm. In other embodiments, a thickness of the bottom plate 121 ranging from 1 mm to 3 mm may be used. Additionally, if the bottom plate 121 is made of steel, the thickness of the bottom plate may be reduced to 0.8 mm. Of course, the thickness of the bottom plate 121 is not limited to the above range, and an appropriate thickness may be selected based on the application and design of the battery pack.

[0080] Furthermore, in terms of battery pack specifications, if the size of the battery pack is large, a relatively large free volume FV can be ensured, whereas if the size of the battery pack is small, the height of the available free volume FV may be small, so it may be necessary to relatively increase the thickness and rigidity of the bottom plate 121.

[0081] In addition, if the size / height of the free volume FV is too small, the gas discharge space becomes small, which may cause a sudden increase in the internal pressure of the battery pack during thermal runaway. Therefore, the size and height of the free volume FV can be determined taking into account the amount of gas generated and the rate of discharge.

[0082] The maximum height of the free volume may be determined based on the degree of damage that the battery cell can withstand while preventing or reducing potential damage to the battery assembly or thermal runaway. For example, if the damage tolerance of the battery cell is 1 mm, the free volume FV may be determined so that the battery cell does not deform more than 1 mm when the bottom plate deforms and presses or contacts the lower surface of the battery cell. In this case, the amount of deformation of the bottom plate may vary depending on the thickness and rigidity of the bottom plate 121. Therefore, the size and height of the free volume may be determined taking into account both the tolerance of the battery cell and the thickness and rigidity of the bottom plate. Furthermore, if the battery cells are housed in a separate case (e.g., a module case) within the battery pack, the possibility of damage to the battery cells protected by the module case is further reduced even if the bottom plate is impacted. Therefore, in this case, the height of the free volume may be reduced.

[0083] The upper surface of the battery assembly 110 may be tightly coupled to the lower surface of the top plate 120A. If there is a gap between the battery assembly 110 and the top plate 120A, high-temperature gas may be introduced into the gap during thermal runaway, causing heat and fire to propagate to the battery assembly 110. Heat and fire may also be transmitted to the top plate 120A, potentially affecting the vehicle interior above the top plate 120A. Therefore, by tightly coupling the upper surface of the battery assembly 110 to the lower surface of the top plate 120A, gas and fire generated inside the battery pack may be guided to and through the free volume FV below the battery assembly 110.

[0084] Referring to FIG. 3 , a TIM layer 130 including a thermal resin may be provided between the battery assembly 110 and the top plate 120A. The TIM layer 130 may be interposed between the battery assembly 110 and the top plate 120A. The TIM layer 130 may fix or bond the battery assembly 110 and the top plate 120A together. Therefore, the battery assembly 110 may be tightly bonded to and supported on the lower surface of the top plate 120A by the TIM layer 130. In addition, the TIM layer 130 may prevent an air gap from forming between the battery assembly 110 and the top plate 120A. The TIM layer 130 may be configured to transfer heat between the battery assembly 110 and the top plate 120A. Therefore, heat generated from the battery assembly 110 may be dissipated to the top plate 120A. If the top plate 120A is equipped with an appropriate cooling device, heat from the battery assembly 110 may be dissipated to the cooling device through the TIM layer 130.

[0085] As a cooling device, the top plate 120A may be provided with a plurality of cooling channels CH1.

[0086] 3 and 4, the top plate 120A may include a plurality of cooling channels CH1 and a plurality of cavities C. Each of the plurality of cooling channels CH1 and the plurality of cavities C may extend in the Y direction.

[0087] According to an exemplary embodiment, the cooling channels CH1 may be configured to provide a path for a cooling fluid to flow. The cooling fluid may be a fluid for cooling the battery assemblies 110, such as, but not limited to, water, air, or a coolant. The cooling channels CH1 may be spaced apart in the X direction. The cooling channels CH1 may be interposed between the cavities C.

[0088] The plurality of cavities C are empty spaces formed inside the top plate 120A. The formation of the plurality of cavities C may reduce the weight of the top plate 120A, thereby increasing the energy density of the battery pack 100. In one embodiment, the energy density of the battery pack 100 may be defined as follows: Energy density of battery pack = Capacity of battery pack / Weight of battery pack. The plurality of cavities C can be spaced apart in the X direction.

[0089] Although not shown for convenience of explanation, the cooling channel CH1 may be connected to a cooling system of a vehicle. In one embodiment, a cooling port may be connected to the cooling channel CH1. The cooling port may be connected to the cooling system of the vehicle by piping or the like.

[0090] When the TIM layer 130 is disposed between the upper surface of the battery assembly 110 and the top plate 120A and the cooling channel CH1 is provided in the top plate 120A, heat generated from the battery assembly 110 can be efficiently cooled. In addition, because the TIM layer 130 and the cooling channel CH1 are disposed on the top of the battery pack, heat generated within the battery pack 100 can be prevented or reduced from being directed toward the vehicle interior, thereby improving the safety of the electric vehicle.

[0091] In the battery pack 100 of FIGS. 3 and 4, the battery assembly 110 is fixed to the top plate 120A with an adhesive member such as a TIM layer 130. However, considering the load of the battery assembly 110, the top plate 120A and the battery assembly 110 may be fastened together with a fastening member. For example, if the battery assembly 110 includes modular cases 112 and 113, the battery assembly 110 may be supported in a suspended state on the top plate 120A by fastening the top plate 120A and the modular cases 112 and 113 together with a fastening member. Alternatively, the battery assembly 110 may be coupled to the top plate 120A using both the TIM layer 130 and the fastening member. In this case, the load of the battery assembly 110 may be more uniformly distributed across the top plate 120A.

[0092] If necessary, the battery assembly 110 may also be coupled to a lower pack housing 120B. For example, the side walls of the lower pack housing 120B may be coupled to the sides of the battery assembly 110. In this case, assembly mounting portions 122a and 123a may be provided on the side walls 122 and 123 to support the sides of the battery assembly. The assembly mounting portions 122a and 123a may protrude from the side walls 122 and 123 to support the sides of the battery assembly perpendicular to the top surface of the battery assembly 110. To this end, the assembly mounting portions 122a and 123a may extend in the X direction, the Y direction, or both the X and Y directions. When the assembly mounting portions 122a and 123a extend in the Y direction, the assembly mounting portions 122a and 123a may be provided on the front and rear side walls of the lower pack housing 120B (not shown).

[0093] The sides of the assembly mounting portions 122a and 123a facing the battery assembly 110 may be in close contact with the sides of the battery assembly to support the battery assembly 110. In this case, the top surface of the battery assembly is supported by the top plate 120A, and the sides are supported by the assembly mounting portions 122a and 123a, so the weight of the battery assembly 110 can be easily distributed. This allows even a heavier battery assembly 110 to be firmly supported within the battery pack 100. The battery assembly 110 may be coupled to the top plate 120A and / or the assembly mounting portions 122a and 123a, regardless of whether a TIM layer is used or not. For example, the battery assembly 110 may be coupled to the top plate 120A and / or the assembly mounting portions 122a and 123a by fastening with fasteners or welding. Alternatively or additionally, an adhesive may be used to secure the battery assembly 110 to the top plate 120A.

[0094] In one embodiment, the top plate 120A may be seated on the upper surfaces of the assembly mounting portions 122a and 123a. The top plate 120A may also be coupled to the side walls 122 and 123 of the lower pack housing 120B. For example, the assembly mounting portions 122a and 123a may be provided for load distribution and mounting of the top plate 120A. The assembly mounting portions 122a and 123a may extend from the side walls toward the inside of the pack. As shown in FIG. 3, a space may be provided between the upper ends of the side walls 122 and 123 and the upper surfaces of the assembly mounting portions 122a and 123a, and the top plate portion 120A may be seated in this space. That is, the top plate may be seated in the space provided on the upper surfaces of the assembly mounting portions 122a and 123a and supported by the assembly mounting portions 122a and 123a. The top plate 120A may be coupled to the upper surfaces and / or side walls 122, 123 of the assembly mounting portions 122a, 123a by fasteners, welding, or other methods. This allows the load of the top plate 120A to be more uniformly distributed to the lower pack housing 120B. The assembly mounting portions 122a, 123a provide support surfaces for both the battery assembly and the top plate. Therefore, the battery assembly and the top plate can be supported simultaneously by the assembly mounting portions 122a, 123a.

[0095] The assembly mounting portions 122a and 123a may also function to block gases in the pack that move to the top plate 120A. For example, by forming the assembly mounting portions 122a and 123a in the form of a square or rectangular frame that surrounds the battery assembly 110, the gases can be prevented from coming into direct contact with the top plate 120A.

[0096] In one embodiment, a predetermined support structure may also be disposed on the bottom plate 121 to distribute the load of the battery assembly and ensure a free volume FV.

[0097] Referring to FIG. 5, according to one embodiment, a plurality of battery supports 150 may be provided on the bottom plate 121 of the lower pack housing 120B.

[0098] In one embodiment, the battery support part 150 has a height in the Z direction. Thus, the battery assembly 110 may be supported by the battery support part such that the upper surface of the bottom plate 121 is spaced apart from the battery assembly 110. By adjusting the height of the battery support part 150, the height and size of the free volume FV may be adjusted.

[0099] The front and / or rear surfaces and / or side surfaces of the battery assembly 110 may be provided with corresponding coupling portions that can be coupled to the battery support part 150. For example, as shown in Fig. 5, protruding coupling parts F1 that can be coupled to the battery support part 150 may be provided on both sides of the battery assembly. Alternatively, as shown in Fig. 6(b), protruding coupling parts F2 that can be coupled to the battery support part 150 may be provided on the front and rear surfaces of the battery module 110A. The protruding coupling parts F1 and F2 and the battery support part may be provided with predetermined fastening holes to which fastening members can be fastened.

[0100] In FIG. 5, when the battery assembly 110 is coupled to the top plate 120A, the assembly mounting portions 122a, 123a of the lower pack housing 120B, and the battery support portion 150 by adhesive members (e.g., the TIM layer 130) and fastening members, a heavier battery assembly 110 can also be installed in the battery pack.

[0101] 5, the battery assemblies 110 may be arranged in two rows in the Y direction, but the present invention is not limited to this. At least one row of battery assemblies 110 may be arranged in the Y direction. Alternatively, at least one battery assembly 110 may be arranged in the X direction.

[0102] 5, the battery support parts 150 may occupy a portion of the free volume FV. The battery support parts 150 may be spaced apart from each other in the battery pack 100 to allow deformation of the bottom plate 121 when an external impact or force is applied to the bottom plate 121. For example, the space between the battery support parts 150 may be a portion of the free volume FV.

[0103] 3 and 4, the lower pack housing 120B may include an exhaust device 140 on one or more of the front, rear, left, and right side walls. In one embodiment, the exhaust device 140 may be provided on the side walls 122 and 123 as shown in FIGS. 3 and 4. The side walls may include exhaust channels and / or exhaust holes connected to the exhaust device 140. The exhaust channels and exhaust holes may be configured to exhaust gas and heat inside the battery pack 100 or to provide a path for the gas and heat to communicate with each other.

[0104] The exhaust device 140 may be configured to slow down thermal propagation by emitting or guiding high-temperature gas inside the battery pack 100 to the outside when at least one of the battery assemblies 110 is in a thermal runway state. In this case, the free volume FV serves as a passage for quickly moving or circulating the gas to the exhaust device 140.

[0105] The battery pack 100 may further include electrical components (not shown in the drawings for clarity of illustration and description). The electrical components may be disposed on the lower pack housing 120B. The electrical components may be disposed between the side wall on which the exhaust device 140 is installed and the battery assembly 110. The electrical components may include any electronic elements necessary to operate the battery pack.

[0106] The electrical components may include, for example, a battery management system (BMS), which may be configured to monitor, balance, and control the battery pack.

[0107] The electrical components may further include a cooling device, a power relay assembly (PRA), a safety plug, etc. The cooling device may include a cooling fan. The cooling fan circulates air inside the battery pack 100 to prevent each of the multiple battery assemblies 110 from overheating.

[0108] 6-10 show perspective views of exemplary embodiments of battery assemblies housed within a battery pack.

[0109] 6(a) and 6(b) show a battery assembly, showing an exploded perspective view (FIG. 6(a)) and an assembled perspective view (FIG. 6(b)) of a battery module 110A.

[0110] The battery module 110A includes a battery cell assembly 111, module cases 112 and 113 that house the battery cell assembly 111, and end plates 114 and 115 that are coupled to the front and rear surfaces of the module cases 112 and 113.

[0111] The battery cell assembly 111 may be configured by stacking, for example, a plurality of pouch-type battery cells 111a, a plurality of prismatic battery cells, or other suitable battery cells that can be arranged to form a battery cell assembly.

[0112] The module case is composed of a lower case 112 and an upper case 113. In Fig. 6, the lower case 112 is shown as a U-shaped frame having side plates 112b and a bottom plate 112a. The shape of the module cases 112 and 113 is not limited to that disclosed in Fig. 6, and it goes without saying that other shapes of module cases can be applied as long as they can stably accommodate the battery cell assembly 111.

[0113] A bus bar frame BFA may be coupled to the front and rear surfaces of the battery cell assembly 111. A bus bar B for connecting electrode leads of the battery cells 111a, a bus bar B for electrically connecting to another battery module or the outside, etc. may be installed on the bus bar frame BFA.

[0114] A front end plate 114 and a rear end plate 115 for protecting the bus bar frame BFA and the battery cell assembly 111 may be located on the front and rear of the battery cell assembly 111. The front end plate 114 and the rear end plate 115 may be coupled to the module cases 112, 113 and / or the bus bar frame BFA.

[0115] If necessary, the module cases 112, 113, for example the upper case 113, may be provided with venting holes H to exhaust gases within the module.

[0116] A TIM layer 130' including a thermal resin may be disposed on the bottom plate 112a of the lower case 112. The TIM layer 130' may be made of the same or different material as the TIM layer 130 disposed between the battery assembly 110 and the top plate 120A. The TIM layer 130' on the bottom plate may fix or attach the battery cell assembly 111 to the bottom plate 112a. In addition, the TIM layer 130' may transfer heat from the battery cell assembly 111 to the bottom plate and the lower case 112.

[0117] In one embodiment, in addition to or instead of the TIM layer 130′, a TIM layer may be located on the inner surface of the upper case 113. That is, a TIM layer may be disposed between the upper case 113 and the upper surface of the battery cell assembly 111.

[0118] The battery cell assembly 111 is mounted on a lower case 112 of a U-shaped frame, and an upper case 113 is joined to the lower case 112 by welding or the like, so that the battery cell assembly 111 can be housed in the module cases 112 and 113. A front end plate 114 and a rear end plate 115 are joined to the front and rear of the battery cell assembly 111 with a bus bar frame BFA interposed therebetween, so that a battery module can be formed as shown in FIG. 6(b).

[0119] A cooling device may be provided in at least one of the upper case 113 and the lower case 112. For example, the upper case 113 or the bottom plate 112a of the lower case facing the upper case 113 may be formed as two plates joined together with a gap therebetween. In this case, a partition may be formed in the gap, and a cooling channel CH2 may be disposed between the partitions as a cooling device. The cooling channel may be located on the side of the case where the TIM layer 130' is formed.

[0120] If desired, a TIM layer 130' and cooling channels CH2 can be disposed in both the upper case 113 and the lower case 112, as shown in FIG.

[0121] 6(b), the battery module 110A may include a coupling portion F2 for coupling to a corresponding structure in the battery pack 100, for example, a battery support portion 150. The coupling portion F2 having a fastening hole h2 for coupling to a battery support portion or the like is provided on both sides of the end plate of the battery module.

[0122] A plurality of the battery modules 110A may be disposed in the battery pack 100.

[0123] When the TIM layer 130' is provided on the lower case 112, as in the battery module 110A shown in FIGS. 6(a) and 6(b), it is preferable that the bottom plate 112a of the lower case be coupled to the top plate 120A of the battery pack shown in FIGS. 3 to 5. That is, the module can be installed in the battery pack with the top case 113 side facing the bottom plate 121 of the battery pack 100 and the bottom plate 112a side facing the top plate 120A. This allows heat generated in the battery cell assembly 111 to be transferred to the lower case 112 via the TIM layer 130'. The heat transferred to the lower case 112 is transferred to the TIM layer 130 disposed on the top plate 120A, and the heat can be cooled by a cooling device of the top plate 120A.

[0124] 7 shows a battery assembly 110B in which a bus bar frame BFA and end plates 114 and 115 are combined with the front and rear surfaces of a battery cell assembly 111. The battery assembly 110B has a moduleless structure in which there is no module case covering the top, bottom, left, and right surfaces of the battery cell assembly 111.

[0125] 7, the battery cells 111a are stacked such that their sides are in contact with each other, and the sides of adjacent battery cells may be secured together with double-sided tape. A securing member may be used to secure the stacked battery cells 111a. For example, the securing member may be a band 116 that is wrapped around the battery cell assembly 111.

[0126] 8 discloses a battery assembly 110C in which a battery cell assembly 111, bus bar assemblies and end plates 114, 115 are coupled to the front and rear surfaces of the stack, and a first side plate 117 and a second side plate 117' are coupled to both sides of the battery cell assembly 111. As shown in FIG. 8, the battery assembly 110C can also bundle the battery cell assemblies 111 with bands 116 to secure the battery cells, the first side plate, and the second side plate.

[0127] The bus bar frame BFA and the end plates 114, 115 may be separate or integrated. The end plates 114, 115 have exposed bus bars B extending from the bus bar frame BFA or from a portion of the bus bar frame BFA, and can be electrically connected to other battery assemblies 110 via the bus bars B.

[0128] 7 and 8, the upper and lower surfaces of the battery cell assembly 111 may be open or exposed. Therefore, one of the open or exposed upper and lower surfaces of the battery cell assembly 111 may be coupled to the lower surface of the top plate 120A of the battery pack 100. For example, a TIM layer 130 may be disposed between the top plate 120A and the battery cell assembly 111, and the battery assembly 110 may be coupled to the top plate 120A. The other of the upper and lower surfaces of the battery cell assembly 111 may be disposed opposite the bottom plate 121 of the battery pack 100 with a gap or space therebetween, and the gap or space may form a free volume FV.

[0129] FIG. 9 shows a battery assembly 110D having a first side plate 117 and a second side plate 117' with complementary interlocking structures.

[0130] The structures of the battery cell assembly 111, the bus bar frame BFA, and the end plates 114, 115 may be substantially similar to the battery assemblies 110B, 110C disclosed in FIGS.

[0131] 9, a first side plate 117 may be located on a first side (e.g., left side) of the battery cell assembly 111. As shown in FIG. 9, a second side plate 117′ may be located on a second side (e.g., right side) of the battery cell assembly 111.

[0132] The first and second side plates 117 and 117' have complementary structures that allow them to easily interlock with each other. For example, as shown in FIG. 9, the first side plate 117 may have a stepped structure with a protrusion P on the upper side and a recess Q on the lower side. As shown in FIG. 9, the second side plate 117' has a stepped structure with a protrusion P' on the lower side and a recess Q' on the upper side. The stepped structures of the first and second side plates 117 and 117' are adapted to interlock with each other. Therefore, the adjacent battery assemblies 110D can be coupled to each other by interlocking the first side plate 117 of one battery assembly 110D with the second side plate 117' of the opposing battery assembly 110D and connecting the first and second side plates 117 and 117' with a fastening member. 9, a plurality of fastening holes 117a are formed through the upper surface of the protrusion P of the first side plate 117, and a plurality of fastening holes 117a' are formed through the protrusion P' on the lower side of the side of the second side plate 117' at positions corresponding to the fastening holes 117a. Therefore, the first side plate 117 and the second side plate 117' can be fastened together by fastening members such as bolts passing through the fastening holes in the first side plate 117 and the second side plate 117'.

[0133] 10 shows that the first side plate 117 and the second side plate 117' of adjacent battery assemblies 110D are coupled to each other through this coupling process. The combination of the first side plate 117 and the second side plate 117' may form a partition wall that separates adjacent battery cell assemblies 111, as shown in FIG. 10. In one embodiment, the combination of the first side plate 117 and the second side plate 117' may be coupled to the battery support 150 shown in FIG. 5. In this case, fastening members such as bolts may pass through fastening holes in the first side plate 117 and the second side plate 117' and be fastened to corresponding fastening holes provided in the battery support 150, thereby coupling the first side plate 117 and the second side plate 117' to the battery support 150.

[0134] 10, the upper and lower surfaces of the battery cell assembly 111 may also be open or exposed. Therefore, one of the open upper and lower surfaces of the battery cell assembly 111 may be coupled to the lower surface of the top plate 120A of the battery pack 100. For example, a TIM layer 130 may be disposed between the top plate 120A and the battery cell assembly 111, and the battery assembly 110 may be coupled to the top plate 120A. The other of the upper and lower surfaces of the battery cell assembly 111 may be disposed opposite the bottom plate 121 of the battery pack 100 with a gap or space therebetween, and the gap or space may form a free volume FV.

[0135] 7 to 10 have a moduleless structure in which at least a portion of the module cases 112 and 113 is removed. Therefore, the structure of the battery assembly 110 can be simplified by the portion of the removed module cases 112 and 113, and the weight of the battery assembly 110 can be reduced. As a result, the energy density of the battery pack 100 employing the battery assembly 110 can be further improved.

[0136] FIG. 11 is an exploded perspective view of another exemplary embodiment of a battery assembly, FIG. 12 is a perspective view showing the bottom plate of the lower case of the battery assembly of FIG. 11, FIG. 13 is a perspective view of the battery assembly of FIG. 11 as viewed from the top side, and FIG. 14 is a perspective view of the battery assembly of FIG. 11 as viewed from the bottom side.

[0137] The battery module 110E shown in FIGS. 11 to 14 is a battery module 110E similar in form to the battery module of FIG.

[0138] In one embodiment, the battery module 110E of FIG. 11 may include a battery cell assembly 111, module cases 112 and 113 that house the battery cell assembly 111, and end plates 114 and 115 that are coupled to the front and rear surfaces of the module cases 112 and 113.

[0139] Two battery cell assemblies 111 are arranged along the longitudinal direction, and the rear surface of the front battery cell assembly 111 is coupled to the front surface of the rear battery cell assembly 111. In the illustrated example, two battery cell assemblies 111 may be connected along the longitudinal direction (X direction), but the present invention is not limited thereto, and two or more battery cell assemblies 111 may be connected along the X direction.

[0140] Two or more battery assemblies 110 may be arranged longitudinally within the battery pack 100. However, in this case, the number of components coupled with each battery cell assembly 111 and the number of module cases accommodating the battery cell assemblies 111 may increase, which may increase manufacturing costs and complicate the assembly of the battery assemblies 110.

[0141] In one embodiment, as shown in FIG. 11, when multiple battery cell assemblies 111 are arranged in the longitudinal direction and the longitudinal assembly of such battery cell assemblies 111 is housed in a single module case (e.g., 112 and 113), the number of parts and manufacturing costs can be reduced.

[0142] 11, a bus bar frame BFA may be coupled to the front and rear surfaces of each battery cell assembly 111. The bus bar frame BFA installed on the rear surface of the front battery cell assembly 111 and the bus bar frame BFA installed on the front surface of the rear battery cell assembly 111 may be mechanically and electrically coupled to each other.

[0143] A front end plate 114 and a rear end plate 115 for protecting the bus bar frame BFA and the battery cell assembly 111 may be located on the front and rear sides of the longitudinal assembly of the battery cell assembly 111. The front end plate 114 and the rear end plate 115 may be coupled to the module cases 112, 113 and / or the bus bar frame BFA. Although two battery cell assemblies 111 are provided, one pair of front and rear end plates is sufficient. Therefore, the number of end plates can be reduced compared to when two battery assemblies 110 are installed in the longitudinal direction.

[0144] The module case may be composed of a lower case 112 and an upper case 113. The lower case 112 is shown as a U-shaped frame having side plates 112b and a bottom plate 112a. However, the shape of the module cases 112 and 113 is not limited to that disclosed in Fig. 11, and other shapes of module cases may be applied as long as they can stably accommodate the battery cell assembly 111.

[0145] In one embodiment, the upper case 113 may include a venting hole to exhaust gases within the module.

[0146] A TIM layer 130' including a thermal resin may be disposed on the bottom plate 112a of the lower case 112. The TIM layer 130' may be made of the same or a different material as the TIM layer 130 disposed between the battery assembly 110 and the top plate 120A. The TIM layer 130' on the bottom plate 112a may fix the battery cell assembly 111 to the bottom plate 112a. In addition, the TIM layer 130' may transfer heat from the battery cell assembly 111 to the bottom plate 112a and the module cases 112, 113.

[0147] If necessary, the TIM layer 130′ may be located on the inner surface of the upper case 113. That is, the TIM layer 130′ may be disposed between the upper case and the upper surface of the battery cell assembly 111.

[0148] The battery cell assembly 111 is mounted on a lower case 112 of a U-shaped frame, and an upper case 113 is joined to the lower case 112 by welding or the like, so that the battery cell assembly 111 can be housed in the module cases 112 and 113. A front end plate 114 and a rear end plate 115 are joined to the front and rear of the battery cell assembly 111 with a bus bar frame BFA interposed therebetween, so that the battery module of this embodiment can be formed as shown in FIGS. 13 and 14 .

[0149] In one embodiment, a cooling device may be provided in at least one of the upper case 113 and the lower case 112. For example, the cooling device may be formed as a structure in which two plates are joined to each other to form a cavity or space between the two plates. For example, the cooling device may be provided in the bottom plate 112a of the upper case or the lower case opposite the upper case. For example, FIG. 12 discloses a bottom plate 112a having such a structure. The bottom plate 112a includes an inner plate 112a-2 facing the battery cell assembly 111 and an outer plate 112a-1 facing the inner plate. As shown in FIG. 12, the inner plate 112a-2 and the outer plate 112a-1 may be formed to have various patterns of protrusions and recesses. However, other suitable protrusions, shapes, and patterns may be used. Therefore, when the inner plate 112a-2 and the outer plate 112a-1 are joined together, a cooling channel CH2 is formed between the inner plate 112a-2 and the outer plate 112a-1 by the protrusion-to-protrusion or protrusion-to-recess combination, as shown in FIG. 12 . For example, the cooling channel CH2 can be formed by the space or volume created when the inner plate 112a-2 and the outer plate 112a-1 are joined together through any suitable bonding process (e.g., brazing). Thus, the cooling channel CH2 is formed between the inner surface of the protrusion and the recessed portion. For clarity of illustration and description, the protrusion and recess are shown only on the top surface of the outer plate 112a-1. However, the inner plate 112a-2 can also include protrusions and recesses on the surface opposite the top surface of the outer plate 112a-1, but this is not limiting. The cooling channel CH2 can be located on the case side on which the TIM layer 130′ is formed.

[0150] In one embodiment, both the upper case 113 and the lower case 112 may have a TIM layer 130' and a cooling device (cooling channel CH2).

[0151] Referring to FIG. 13, the battery module 110E may include a coupling portion for coupling to a corresponding structure, for example, the battery support 150, in the battery pack 100. Protruding coupling portions F1 having fastening holes h1 for coupling to the battery support 150 may be provided along both side plates 112b of the lower case 112 (for clarity of description and illustration, only one side plate 112b is shown, and the opposite side plate 112b is not shown). As shown in FIG. 13, the protruding coupling portions F1 may be spaced apart from each other along the length of the battery module. The number and shape of coupling portions provided on the left and right side plates 112b of the battery module 110E may be the same or different. Four protruding coupling portions F1 may be arranged along the length of the side plate 112b in FIG. 13. Meanwhile, two protruding coupling portions F1 may be arranged along the length of the side plate 112b in FIG. 14, and each protruding coupling portion F1 may be provided with a plurality of fastening holes h1.

[0152] In one embodiment, as shown in FIGS. 15 and 16, a plurality of the battery modules 110E can be arranged in the battery pack 101.

[0153] 11 , when the lower case TIM layer 130′ and the cooling channel CH2 are provided, it is preferable that the bottom plate 112a of the lower case 112 is coupled to the top plate 120A of the battery pack 100 or 101. That is, the module can be installed in the battery pack with the upper case 113 side facing the bottom plate 121 of the battery pack 100 or 101 and the bottom plate 112a side facing the top plate 120A. This allows heat from the battery cell assembly 111 to be transferred to the lower case via the lower case TIM layer 130′. The heat transferred to the lower case 112 can be cooled by the cooling channel CH2 of the lower case 112.

[0154] This allows the heat transferred from the battery module 110E to the top plate 120A to be cooled, thereby protecting passengers in the vehicle compartment.

[0155] In one embodiment, if the top plate 120A is provided with a cooling device CH1, this cooling effect can be further increased. For example, by providing cooling devices in both the lower case of the battery assembly 110 and the top plate 120A of the pack housing 120, heat transferred to the upper part of the pack 100 or 101 can be more reliably cooled. Therefore, the vehicle interior protection effect is further increased. For example, heat can be transferred along the path of the TIM layer 130′-cooling channel CH2-TIM layer 130-cooling channel CH1.

[0156] 15 and 16 are cross-sectional views of a battery pack 101 including the battery assembly (battery module) of FIGS.

[0157] As shown in the figure, the bottom plate 112a of the lower case of the battery module 110E is suspended and supported on the top plate 120A of the pack via a TIM layer 130'. In addition, the top surface of the upper case 113 of the battery module may be spaced apart from the bottom plate 121, and this space may form a free volume FV.

[0158] Two battery cell assemblies 111 are installed in the longitudinal direction within the battery module 110E, and a required electrical capacity can be obtained with a simple structure.

[0159] In the battery pack of this embodiment, even if an impact occurs to the battery pack 101 from below, the free volume FV can absorb, for example, deformation of the bottom plate 121, thereby preventing damage to the battery assembly 110.

[0160] In addition, even when gas and flames are generated due to thermal runaway, the free volume FV serves as a venting passage, allowing the gas to be quickly released or circulated to the outside of the battery pack. In this case, an exhaust device 140 can be provided on the side wall of the battery pack as shown in FIG. 3. This makes it easier to exhaust the gas.

[0161] In addition, a thermal resin layer such as a TIM layer 130 is provided on the underside of the top plate 120A of the battery pack, so that heat from the battery assembly 110E can be transferred to the top plate 120A. The top plate 120A has a cooling channel CH1, so that the heat can be cooled or easily discharged to the outside.

[0162] FIG. 17 is a perspective view of another exemplary embodiment of a battery assembly 110F.

[0163] FIG. 17 shows the structure of a battery assembly 110F including a prismatic battery cell 111a.

[0164] 17 may include a battery cell assembly 111, a first side plate 117, a second side plate 117′, a bus bar frame BFA, and a bus bar attached to the bus bar frame BFA. Also, an insulating cover IC may be provided on the bus bar B for insulation.

[0165] Prismatic battery cells 111a may be stacked in the X direction to form a battery cell assembly 111. A bus bar frame BFA (bus bar carrier) may be disposed on an upper surface of the battery cell assembly 111. Bus bars B, such as inter-bus bars and terminal bus bars, may be mounted on the bus bar frame BFA. To fix the battery cell assembly 111, one or more bands (not shown for clarity of illustration and description) may be provided along the periphery of the battery cell assembly. Also, as shown in FIG. 17, a front end plate 114 and a rear end plate 115 may be provided to cover the front and rear ends of the battery cell assembly 111.

[0166] The first side plate 117 and the second side plate 117' may have coupling portions for coupling to corresponding structures in the battery pack, for example, the battery support 150. That is, protruding coupling portions F1 having fastening holes h1 may be provided along the longitudinal direction (X direction) of the first side plate 117 and the second side plate 117'. In one embodiment, the protruding coupling portions F1 may be spaced apart from each other along the longitudinal direction of the battery module 110F. The number and shapes of coupling portions provided on the first side plate 117 and the second side plate 117' of the battery assembly 110F may be the same or different.

[0167] The battery assembly 110F of this embodiment may be housed in the pack housing 120 of the battery pack 100 or 101, and one side of the battery assembly 110F may be suspended and supported on the top plate 120A of the pack housing. For example, at least one of the upper and lower sides of the battery cell assembly 111 may be coupled to the lower side of the top plate 120A, for example, via a TIM layer 130. If necessary, the battery assembly 110F may be fastened to the top plate 120A and / or the lower pack housing 120B. Alternatively, the battery assembly 110F may be reliably supported within the pack by coupling the protruding coupling portion F1 of the battery assembly 110F to the battery support portion 150 provided on the bottom plate 121 of the pack 100 or 101. In this case, a free volume FV is provided between the lower side of the battery assembly 110F and the bottom plate 121.

[0168] Although not shown, the battery assembly 110F of FIG. 17 may additionally include an upper case covering the upper surface of the battery cell assembly 111 and / or a lower case covering the lower surface of the battery cell assembly 111.

[0169] For example, an upper case may be located on the insulating cover IC. Alternatively, a lower case may be located below the battery cell assembly 111. The upper case and / or the lower case may be coupled to the first side plate 117 and the second side plate 117′. In this case, the upper case, the lower case, the first side plate, and the second side plate may form a module case of the battery cell assembly 111.

[0170] The battery assembly 110F having an upper case or a lower case can be supported with the upper case side or the lower case side suspended on the top plate 120A of the pack housing 100 or 101.

[0171] In one embodiment, a cooling device may be provided in the upper case or the lower case, for example, a case side including a cooling device may be coupled to the top plate 120A.

[0172] In one embodiment, the case of the battery assembly 110F facing the free volume FV may have a venting hole, which allows gas generated from the battery cell assembly 111 to be discharged to the outside of the battery assembly 110F.

[0173] FIG. 18 is a schematic diagram showing the structure of an electric vehicle 200 equipped with a battery pack according to the present disclosure.

[0174] For the sake of simplicity, only the vehicle body frame 210 that forms the lower skeleton of the vehicle, the battery pack 101 that is coupled to the vehicle body frame 210, and the tires are shown.

[0175] The vehicle body frame 210 may be fitted with a battery pack 100 or 101 according to the present disclosure. The battery pack 100 or 101 has a structure in which the battery assembly 110 is suspended and supported on the top plate 120A of the battery pack, rather than a conventional structure in which the battery assembly is installed at the bottom of the pack. That is, there is no space between the battery assembly (battery module 110E) and the top plate 120A, preventing gas generated in the battery assembly from being transferred to the vehicle interior above the vehicle. The gas is guided to a free volume FV located between the battery assembly 110 and the bottom plate 121 of the battery pack. That is, because there is no space on the upper side of the battery pack, the gas is guided to the free volume FV on the lower side of the battery pack. The gas flows through the free volume FV and can be discharged to the lower part of the vehicle via an exhaust device installed in the battery pack.

[0176] The bottom plate 121 of the battery pack is attached to or supported by the body frame 210. In this case, an impact may occur from the body frame 210 at the bottom of the vehicle, which may cause the bottom plate 121 to deform. The battery pack of the present disclosure includes a free volume FV between the battery assembly 110 and the bottom plate 121. Therefore, even if the bottom plate 121 deforms, the battery assembly 110 can be prevented from being damaged.

[0177] In this way, the battery pack and the electric vehicle equipped with the battery pack of the present disclosure can enhance passenger safety, protect the battery assembly 110, which is a core component, and improve the durability of the battery pack and the electric vehicle.

[0178] The present disclosure has been described in more detail above through drawings and embodiments, etc. However, the configurations described in the drawings or embodiments in this specification are merely one embodiment of the present disclosure and do not represent all of the technical ideas of the present disclosure, and therefore, there may be various equivalents and modifications that can replace them at the time of filing this application. [Explanation of symbols]

[0179] 100, 101: Battery pack 110: Battery assembly 120: Pack housing 120A: Top plate 120B: Lower pack housing 130:TIM layer 140: Exhaust system 200: Electric vehicles 210: Body frame

Claims

1. a housing including an opening and a first surface facing the opening; a battery assembly housed in the housing; a first cover covering the opening and coupled to the housing, a first side of the battery assembly is coupled to a first side of the first cover; The second side of the battery assembly is spaced apart from the first surface of the housing.

2. The battery pack of claim 1 , wherein a first side of the battery assembly is attached to a first side of the first cover.

3. The battery pack of claim 1 , further comprising a first layer between the battery assembly and the first cover.

4. the first cover includes a cooling channel between a first side and a second side of the first cover; The battery pack according to claim 1 , wherein the first side of the first cover faces the second side of the first cover.

5. The battery pack according to claim 1 , wherein the battery assembly is fastened to the first cover and / or the housing.

6. the housing further includes a sidewall coupled to a first edge of the first surface; the housing includes a mounting portion on the side wall; The battery pack according to claim 1 , wherein the battery assembly is coupled to the mounting portion.

7. The battery pack according to claim 6 , wherein the first cover is coupled to the mounting portion.

8. The battery pack of claim 1 , wherein the housing further includes an exhaust.

9. the housing further includes a battery support structure on the first surface; The battery pack according to claim 1 , wherein the battery assembly is coupled to the battery support structure.

10. The battery assembly includes: a cell assembly including a battery cell; The battery pack according to claim 1 , further comprising: a bus bar coupled to a first side of the cell assembly.

11. the battery assembly further includes a second cover; The battery pack according to claim 10 , wherein the second cover is coupled to a second side of the cell assembly.

12. further comprising a first layer; the first layer comprises a thermal interface material; the thermal interface material comprises a thermal resin; The battery pack of claim 11 , wherein the first layer is located on a surface of the second cover.

13. the battery assembly includes a third cover coupled to a third side of the cell assembly; The battery pack of claim 11 , further comprising: a cooling portion located on at least one of the second cover or the third cover.

14. The battery assembly includes: The battery pack according to claim 10 , further comprising: a second cover coupled to a second side of the cell assembly; and a third cover coupled to a third side of the cell assembly.

15. the second cover has a first shape and the third cover has a second shape; 15. The battery pack of claim 14, wherein the first shape and the second shape are configured to mate with each other.

16. The battery assembly includes: a first cell assembly and a second cell assembly; the first cell assembly includes a first bus bar; the second cell assembly includes a second bus bar; The battery pack of any one of claims 1 to 15, wherein the first cell assembly is coupled to the second cell assembly via the first bus bar and the second bus bar.

17. a housing including an opening and a surface facing the opening; a cover configured to cover the opening; a battery pack including a battery assembly coupled to the cover and spaced apart from the surface; a frame; the battery pack is housed within the frame; a vehicle cabin is located above at least a first portion of the battery pack; The frame is positioned below at least a second portion of the battery pack.

18. The battery pack of claim 10 , wherein the battery assembly further comprises a bus bar frame including the bus bar.

19. a cell assembly including a battery cell; a first cover coupled to a first side of the cell assembly; a second cover coupled to a second side of the cell assembly; a layer interposed between the second cover and the second side of the cell assembly; the first cover includes a first cooling portion; The second cover includes a second cooling section, and the battery assembly.

20. the first cooling section includes a venting opening; The battery assembly of claim 19 , wherein the second cooling portion includes a cooling channel.

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