Battery module and battery pack including same

Abstract

The battery module of the present invention includes a battery cell stack including a plurality of battery cells, a module frame including a bottom and two opposing side surfaces and accommodating the battery cell stack inside, a thermally conductive resin layer disposed between one surface of the module frame and the battery cell stack, a pad disposed at least at one end of the one surface of the module frame, and a complementary material disposed between the battery cell stack and the pad, the complementary material filling the space between the battery cell stack and the pad.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0107114, filed August 16, 2023, and Korean Patent Application No. 10-2024-0097888, filed July 24, 2024, and all contents disclosed in the documents of said Korean patent applications are incorporated herein by reference.

[0002] The present invention relates to a battery module and a battery pack including the same, and more particularly to a battery module that prevents overflow of a thermally conductive resin and a battery pack including the same. [Background technology]

[0003] Secondary batteries, which are easy to apply to various products and have electrical properties such as high energy density, are widely used not only in portable devices but also in electric vehicles or hybrid vehicles powered by electrical sources, power storage devices, etc. These secondary batteries are attracting attention as a new energy source that is environmentally friendly and improves energy efficiency because they do not produce any by-products due to energy use, in addition to their primary advantage of dramatically reducing the use of fossil fuels.

[0004] While small mobile devices use one, two, three, or four battery cells per device, medium- to large-sized devices such as automobiles require high output and large capacity. Therefore, medium- to large-sized battery modules, which electrically connect multiple battery cells, are used.

[0005] Since it is preferable that medium- to large-sized battery modules be manufactured with small size and weight if possible, prismatic batteries, pouch-shaped batteries, etc., which can be stacked with high integration and have a small weight relative to capacity, are mainly used as battery cells for medium- to large-sized battery modules. Meanwhile, the battery module may include a frame member that has open front and rear surfaces and houses the battery cell stack in an internal space to protect the cell stack from external impact, heat, or vibration.

[0006] FIG. 1 is an exploded perspective view showing a conventional battery module.

[0007] FIG. 2 is a perspective view of a conventional battery cell stack as seen from below.

[0008] FIG. 3 is a cross-sectional view showing a cross section of the battery module of FIG. 1 taken along the YZ plane.

[0009] FIG. 4 is an enlarged cross-sectional view of a part of FIG.

[0010] 1 and 2, a conventional battery module 100c includes a battery cell stack 12 including a plurality of battery cells 11 and a module frame 30 that houses the battery cell stack 12. The battery cell stack 12 may further include compression pads 10 disposed between the plurality of battery cells 11, as shown in FIG.

[0011] The battery module 100c may further include an upper plate (not shown) that is combined with the module frame 30 and covers the upper part of the battery cell stack 120, end plates (not shown) that are respectively located on the front and rear sides of the battery cell stack 12, and a bus bar frame 13 that is located between the battery cell stack 12 and the end plates (not shown).

[0012] A conventional module frame 30 includes a bottom portion 30a and two opposing side portions 30b. The bottom portion 30a may have a shape that is open at the front and rear along the X-axis direction and open at the top along the Z-axis direction. The side portions 30b may extend in the Z-axis direction on both sides of the bottom portion 30a. The bottom portion 30a and the side portions 30b form a space for accommodating the battery cell stack 12.

[0013] Meanwhile, before the battery cell stack 12 is attached to the module frame 30, a thermally conductive resin layer 31 can be formed between the module frame 30 and the battery cell stack 12. The thermally conductive resin layer 31 can transfer heat generated from the battery cell stack 12 to the outside of the battery module and can serve to fix the battery cell stack within the battery module.

[0014] The thermally conductive resin layer 31 can be formed by applying and curing a thermally conductive resin to the bottom 30a of the module frame 30. Meanwhile, pads 32 can be placed on the bottom 30a to prevent the thermally conductive resin from overflowing outside of the required area when applying the thermally conductive resin. The pads 32 are placed on both ends of the bottom 30a and control the application direction of the thermally conductive resin. However, as the thermally conductive resin spreads, it may overflow the pads 32 and spread outside of the application area.

[0015] 3 and 4, after the battery cell stack 12 is attached to the module frame 30, an incompletely filled space SP exists between the pad 32 and the battery cell stack 12. During the application process, the thermally conductive resin may overflow from the pad 32 through this space SP. This may damage the battery cell stack 12, degrade the performance of the battery cell stack 12, and pose a safety risk.

[0016] Therefore, it is necessary to develop a structure that can control the overflow of the thermal conductive resin during the formation of the thermal conductive resin layer. Summary of the Invention [Problem to be solved by the invention]

[0017] The problem to be solved by the present invention is to provide a battery module in which overflow of thermally conductive resin is prevented, and a battery pack including the same.

[0018] However, the problems to be solved by the embodiments of the present invention are not limited to the above problems, and can be variously expanded within the scope of the technical ideas included in the present invention. [Means for solving the problem]

[0019] The battery module of the present invention includes a battery cell stack including a plurality of battery cells; a module frame including a bottom and two opposing side surfaces and accommodating the battery cell stack inside; a thermally conductive resin layer disposed between one surface of the module frame and the battery cell stack; a pad disposed on at least one end of the one surface of the module frame; and a complementary material disposed between the battery cell stack and the pad; the complementary material filling the space between the battery cell stack and the pad.

[0020] In one embodiment, the one surface may be the top surface of the bottom portion.

[0021] In one embodiment, the one surface may be an inner surface of the side portion.

[0022] In one embodiment, the complementary material may include a resin.

[0023] In one embodiment, the thermally conductive resin layer may not overflow outside the pad and the complementary material.

[0024] In one embodiment, the complementary material may be first provided on one side of the battery cell stack in an uncured state, and then compressed and cured between the battery cell stacks and the pad when the battery cell stack is placed in the module frame.

[0025] In one embodiment, the complementary material may be polyurethane foam (PU foam).

[0026] In one embodiment, the complementary material may be silicone.

[0027] In one embodiment, a plurality of the pads may be arranged on both ends of the one surface of the module frame, and the thermally conductive resin layer may be arranged between the pads.

[0028] The battery pack of the present invention includes the battery module described above. [Effects of the Invention]

[0029] The battery module of the present invention includes a complementary material that fills the space between the battery cell stack and the pad, preventing the thermally conductive resin from flowing into unintended spaces when the battery cell stack is inserted into the module frame. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 is an exploded perspective view showing a conventional battery module. [Figure 2] FIG. 2 is a perspective view of a conventional battery cell stack as seen from below. [Figure 3] FIG. 3 is a cross-sectional view showing a cross section of the battery module of FIG. 1 taken along the YZ plane. [Figure 4] FIG. 4 is an enlarged cross-sectional view of a part of FIG. [Figure 5] FIG. 5 is a plan view showing a battery pack according to one embodiment. [Figure 6] FIG. 6 is an exploded perspective view showing a battery module according to one embodiment. [Figure 7] FIG. 7 is a perspective view showing a battery module in which the components shown in FIG. 6 are combined. [Figure 8] FIG. 8 is a perspective view of the battery module of FIG. 6 as seen from below. [Figure 9]FIG. 9 is a cross-sectional view showing the cross section of the battery module of FIG. 7 taken along the YZ plane. [Figure 10] FIG. 10 is an enlarged cross-sectional view of a part of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0031] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention may be embodied in various different forms and is not limited to the embodiments set forth herein.

[0032] In order to clearly explain the present invention, parts that are not necessary for the explanation are omitted, and the same reference numerals are used throughout the specification to refer to the same or similar components.

[0033] In addition, the size and thickness of each component shown in the drawings are arbitrarily shown for the convenience of explanation, and the present invention is not necessarily limited to those shown. Thicknesses are exaggerated in the drawings to clearly show various layers and regions. In the drawings, the thicknesses of some layers and regions are exaggerated for the convenience of explanation.

[0034] Furthermore, when a layer, film, region, plate, or other part is said to be "on" another part, this does not only mean that it is "directly on" that other part, but also includes cases where there is another part in between. Conversely, when a part is said to be "directly on" another part, it means that there is no other part in between. Furthermore, being "on" a reference part means being located above or below the reference part, and does not necessarily mean being located "on" in the opposite direction of gravity.

[0035] Also, throughout the specification, when a part is said to "comprise" a certain element, this does not mean that it excludes other elements and may further include other elements, unless specifically stated to the contrary.

[0036] Also, throughout the specification, "on a plane" means when the part in question is viewed from above, and "on a cross section" means when the part in question is cut vertically and viewed from the side.

[0037] FIG. 5 is a plan view showing a battery pack according to one embodiment.

[0038] 5 , a battery pack 1000 according to one embodiment includes a battery module 100, a pack frame 1100, a busbar assembly 1200, a battery disconnect unit (BDU) module 1300 for controlling electrical connection between the battery modules 100, and a battery management system (BMS) module 1400 for monitoring and controlling the operation of the battery modules 100. At least one busbar assembly 1200 according to this embodiment electrically connects at least one of the battery modules 100 together, the battery modules 100 and the BDU module 1300 together, the battery modules 100 and the BMS module 1400 together, and the BDU module 1300 and the BMS module 1400 together. Specifically, a plurality of battery modules 100 can be housed in the pack frame 1100, and the busbar assembly 1200 can electrically connect the battery modules 100 together and the battery modules 100 and the BDU module 1300 together. That is, the busbar assembly 1200 according to the present embodiment can serve as an HV (High Voltage) connection. Here, the HV connection refers to a connection that functions as a power source for supplying power that requires high voltage, and refers to a connection between battery cells or between battery modules.

[0039] Meanwhile, the BDU module 1300 is a member for controlling the electrical connection of the battery module 100 and can cut off the power supply between the power conversion device and the battery module 100 .

[0040] The BDU module 1300 can ensure the safety of the battery pack 1000 by cutting off the power supply to the battery pack 1000 when a condition occurs in which the current exceeds a set range.

[0041] Meanwhile, the LV connecting member 1200′ according to the present embodiment may be responsible for electrical connection between the battery module 100 and the BMS module 1400. The electrical connection here is a low voltage (LV) connection, which refers to a sensing connection for detecting and controlling the voltage and temperature of the battery module 100. Specifically, sensors and the like are disposed inside the battery module 100, and real-time temperature and voltage information of the battery module 100 is transmitted to the BMS module 1400 through the LV connecting member 1200′. The real-time operating status of the battery module 100 can be monitored and controlled through the BMS module 1400. Although not specifically shown, an HV current sensor may be integrated into the BMS module 1400. In this case, the busbar assembly according to the present embodiment may be responsible for electrical connection between the battery module 100 and the BMS module 1400 or between the BDU module 1300 and the BMS module 1400.

[0042] Hereinafter, a battery module according to an embodiment will be described with reference to Figures 6 to 10. However, a battery module 100 described below is one exemplary structure of a battery module including a battery cell stack 120, and various types of battery modules including the battery cell stack 120 can be applied.

[0043] FIG. 6 is an exploded perspective view showing a battery module according to one embodiment.

[0044] FIG. 7 is a perspective view showing a battery module in which the components shown in FIG. 6 are combined.

[0045] FIG. 8 is a perspective view of the battery module of FIG. 6 as seen from below.

[0046] FIG. 9 is a cross-sectional view showing the cross section of the battery module of FIG. 7 taken along the YZ plane.

[0047] FIG. 10 is an enlarged cross-sectional view of a part of FIG.

[0048] 6 and 7 , a battery module 100 according to this embodiment includes a battery cell stack 120 including a plurality of battery cells 110 and a module frame 300 that houses the battery cell stack 120. The battery cell stack 120 includes a plurality of battery cells 110 stacked in one direction. For example, the plurality of battery cells 110 may be stacked in the Y-axis direction as shown in FIG. 6 . The battery cells 110 may be pouch-type battery cells, but the present invention is not limited thereto. Meanwhile, the battery cell stack 120 may further include compression pads 111 disposed between the plurality of battery cells 110 as shown in FIG. 9 . The compression pads 111 may include foam or the like and may absorb expansion of the battery cells 110, thereby improving the structural stability of the battery module 100.

[0049] The battery module 100 may further include an upper plate 400 that is combined with the module frame 300 and covers the upper part of the battery cell stack 120, end plates 150 that are respectively located on the front and rear sides of the battery cell stack 120, and a bus bar frame 130 that is located between the battery cell stack 120 and the end plate 150.

[0050] The battery module 100 includes a thermally conductive resin layer 310 positioned between the battery cell stack 120 and the module frame 300. The thermally conductive resin layer 310 may be a thermally conductive adhesive. Various organic and / or inorganic resins, such as a thermally conductive epoxy adhesive, a thermally conductive silicone adhesive, or a thermally conductive urethane adhesive, may be used as the thermally conductive adhesive. The thermally conductive resin layer 310 serves to adhesively fix the battery cell stack 120 within the battery module 100. Furthermore, since the thermally conductive resin layer 310 has higher thermal conductivity than typical adhesives, it can further increase the amount and speed of heat transfer between the battery cell stack 120 and the module frame 30 and serve as a heat dissipation layer that transfers heat generated from the battery cell stack 120 to the outside of the battery module 100. The thermally conductive resin layer 310 is positioned between the battery cell stack 120 and one side of the module frame 300.

[0051] The module frame 300 may have an open top, front, and rear surface. The module frame 300 may be a U-shaped frame. The open sides of the module frame 300 are referred to as the first and second sides, respectively. The module frame 300 has a plate-like structure bent to continuously surround the adjacent front, bottom, and rear surfaces of the remaining outer surface, excluding the surfaces of the battery cell stack 120 corresponding to the first and second sides. The top surface facing the bottom surface of the module frame 300 is open.

[0052] A pad 320 is disposed on the one surface of the module frame 300 to guide the application position of the thermally conductive resin during the process of forming the thermally conductive resin layer 310 .

[0053] The module frame 300 includes a bottom 300a and two opposing side portions 300b. As described above, the thermally conductive resin layer 310 is disposed between one surface of the module frame 300 and the battery cell stack 120. The one surface of the module frame 300 may be one of the upper surface of the bottom 300a and the inner surfaces of the side portions 300b. The upper surface of the bottom 300a may face the lower surface of the battery cell stack 120. The inner surfaces of the side portions 300b may face the front and rear surfaces of the battery cell stack 120. In one embodiment, the thermally conductive resin layer 310 may be disposed between the upper surface of the bottom 300a of the module frame 300 and the battery cell stack 120. Alternatively, in another embodiment, the thermally conductive resin layer 310 may be disposed between the inner surfaces of the side portions 300b of the module frame 300 and the battery cell stack 120.

[0054] Hereinafter, as an example, a description will be given of a structure in which the thermally conductive resin layer 310 is disposed on the upper surface of the bottom portion 300a of the module frame 300. That is, a structure in which the thermally conductive resin layer 310, the pad 320, and a supplementary material RS (described later) are disposed on the bottom portion 300a will be described as an example.

[0055] However, the present invention is not limited thereto, and the thermally conductive resin layer 310 may be disposed on the inner surface of the side portion 300b instead of the bottom portion 300a. In this case, the description of the relationship between the thermally conductive resin layer 310, the pad 32, and the complementary material RS described below also applies.

[0056] In one embodiment, referring to FIG. 6, the thermally conductive resin layer 310 is formed by being applied on the bottom portion 300a in a lengthwise direction along the X-axis, which is the extension direction of the bottom portion 300a.

[0057] The pads 320 are disposed on at least one end of the bottom portion 300a. For example, the pads 320 may be disposed on both ends of the bottom portion 300a to guide the application position of the thermally conductive resin during the formation of the thermally conductive resin layer 310 or to prevent the thermally conductive resin from spilling out of the pads 320. While FIG. 6 shows one pad 320 formed on each end of the bottom portion 300a, the size, position, and number of the pads 320 may be modified in design depending on the amount of thermally conductive resin to be applied. The pads 320 may have insulating properties. Furthermore, the pads 320 may be formed of a material such as polyurethane foam or rubber so that the pads 320 that contact the bottom surface of the battery cell stack 120 are compressed when the battery cell stack 120 is inserted into the module frame 300.

[0058] The upper plate 400 has a single plate-shaped structure that surrounds the upper surface except for the front, bottom, and rear surfaces that are surrounded by the module frame 300. The module frame 300 and the upper plate 400 may be joined by welding or the like with corresponding corners in contact with each other to form a structure that surrounds the battery cell stack 120. That is, the module frame 300 and the upper plate 400 may have joint parts CP formed by a joining method such as welding at corresponding corners.

[0059] 6 , 8 , 9 , and 10 , a support material RS is disposed between the battery cell stack 120 and the pad 320 in one embodiment. The pad 320 is omitted in FIG. 8 to illustrate the position where the support material RS is formed. The support material RS may be disposed along the Y-axis direction, which is the extension direction of the pad 320. The support material RS serves to fill a space SP (see FIG. 3 ) between the battery cell stack 120 and the pad 320 when the battery cell stack 120 is placed in the module frame 300. The space SP (see FIG. 3 ) refers to the gap between the battery cell stack 120 and the pad 320. The support material RS prevents the thermally conductive resin layer 310 from spilling out of the pad 320 through the space SP (see FIG. 3 ).

[0060] The complementary material RS may include resin. For example, the complementary material RS may be polyurethane foam (PU foam) formed by applying a polyurethane spray or the like to one surface, for example, the lower surface, of the battery cell stack 120. Alternatively, the complementary material RS may be silicone formed on one surface, for example, the lower surface, of the battery cell stack 120 using a silicone gun or the like. However, the material of the complementary material RS is not limited to the above and may be any material as long as it has insulating properties and a predetermined compressibility.

[0061] The complementary material RS may be first provided in an uncured state on one surface, for example, the bottom surface, of the battery cell stack 120, and then compressed and cured between the battery cell stack 120 and the pad 320 when the battery cell stack 120 is placed in the module frame 300. The complementary material RS may fill the space SP (see FIG. 3 ) between the battery cell stack 120 and the pad 320 during the compression process.

[0062] The battery module 100 of the present invention includes a complementary material RS disposed between the battery cell stack 120 and the pad 320 disposed on the bottom 300a of the module frame 300, and the complementary material RS can fill the space between the battery cell stack 120 and the pad 320, thereby effectively preventing the overflow of the thermally conductive resin. This can prevent defects in the battery module 100 caused by the thermally conductive resin layer 310 being formed in unintended locations.

[0063] In this embodiment, terms indicating directions such as front, back, left, right, up and down are used, but these terms are merely for convenience of explanation and may change depending on the position of the target object, the position of the observer, etc.

[0064] One or more battery modules according to the present embodiment described above may be attached together with various control and protection systems such as a BMS (Battery Management System), a BDU (Battery Disconnect Unit), and a cooling system to form a battery pack.

[0065] The battery module or battery pack can be applied to various devices, specifically, transportation means such as electric bicycles, electric cars, and hybrids, and energy storage systems (ESS), but is not limited thereto, and can be applied to various devices that can use secondary batteries.

[0066] Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the following claims also fall within the scope of the present invention. [Explanation of symbols]

[0067] 100: Battery module 120: Battery cell stack 110: Battery cell 111: Compression pad 300:Module Frame 300a: bottom 300b: Side part 310: Thermally conductive resin layer 320: Pad 400: Upper plate RS: Complementary material

Claims

1. a battery cell stack including a plurality of battery cells; a module frame including a bottom portion and two opposing side portions, the module frame housing the battery cell stack therein; a thermally conductive resin layer disposed between one surface of the module frame and the battery cell stack; a pad disposed at at least one end of the one side of the module frame; and a complement disposed between the battery cell stack and the pad; Including, The battery module, wherein the complement fills a space between the battery cell stack and the pad.

2. The battery module according to claim 1 , wherein the one surface is an upper surface of the bottom portion.

3. The battery module according to claim 1 , wherein the one surface is an inner surface of the side surface portion.

4. The battery module according to claim 1 , wherein the complementary material includes a resin.

5. The battery module according to any one of claims 1 to 4, wherein the thermally conductive resin layer does not overflow outside the pad and the complementary material.

6. 2. The battery module according to claim 1, wherein the complementary material is first provided on one side of the battery cell stack in an uncured state, and then compressed and cured between the battery cell stacks and the pads when the battery cell stack is housed in the module frame.

7. The battery module according to claim 1 , wherein the complementary material is polyurethane foam.

8. The battery module according to claim 1 , wherein the complementary material is silicon.

9. a plurality of the pads are arranged on both ends of the one surface of the module frame; The battery module according to claim 1 , wherein the thermally conductive resin layer is disposed between the pads.

10. A battery pack comprising the battery module according to claim 1.

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