Battery pack with foam kit assembly and manufacturing method thereof

Abstract

The present invention discloses a battery pack and a manufacturing method thereof, which include a battery pack case having an internal space, a plurality of battery cells housed in the internal space of the battery pack case, arranged horizontally, and each extending in the vertical direction, a foam kit assembly housed in the internal space of the battery pack case so as to be positioned above the plurality of battery cells and isolated from the outside, and foam that is discharged from the foam kit assembly and filled between the internal surface of the battery pack case and the foam kit assembly, and which allows the foam to be uniformly filled inside the battery pack case.

Description

[Technical field]

[0001] The present invention relates to a battery pack with a foam kit assembly and a manufacturing method thereof, and more particularly, to a battery pack with a foam kit assembly capable of uniformly filling foam inside a battery pack case and a manufacturing method thereof. [Background technology]

[0002] A secondary battery is a rechargeable battery that is used in a wide variety of fields, from smartphones to electric vehicles. In this case, the secondary battery is used in the form of a single battery cell or in the form of a battery pack in which multiple battery cells are connected, depending on the type of device in which it is used. For example, a secondary battery used in a small device such as a smartphone is used in the form of a single battery cell. In addition, a secondary battery used in a medium-sized or large device such as an electric vehicle is used in the form of a battery pack in which multiple battery cells are connected.

[0003] Meanwhile, when multiple battery cells are to be configured into a medium- or large-sized battery pack, a large number of battery cells are required to meet the output voltage and charging capacity required for the medium- or large-sized device. These battery cells are manufactured in a dense form in a small space, with foam packed between them.

[0004] The foam serves many purposes, including blocking heat transfer between multiple battery cells, directing materials leaking from a failed battery cell away from other battery cells, and preventing short circuits between multiple battery cells.

[0005] Such foam is injected into the battery pack housing through a number of ports in the sidewall of the battery pack housing, but since the intervals between the battery cells are narrow in order to increase the energy density of the battery pack, it is not easy to uniformly fill the foam between the battery cells densely arranged in the battery pack housing. In addition, since the foam generally used in the battery pack has high viscosity, it is difficult to inject the foam deeply from the outer periphery of the battery pack housing to the center of its interior through the ports, and even if it is injected deeply, it is difficult to ensure uniform distribution of the foam in the height direction of the battery cells.

[0006] The background art of the present invention is described in the following patent documents: [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Korean Patent Publication No. 10-2019-0097231 [Patent Document 2] Korean Patent No. 10-0897899 Summary of the Invention [Problem to be solved by the invention]

[0008] The present invention provides a battery pack with a foam kit assembly, which can uniformly fill foam inside a battery pack case, and a manufacturing method thereof. [Means for solving the problem]

[0009] A battery pack with a foam kit assembly according to an embodiment of the present invention comprises: a battery pack case having an internal space; a plurality of battery cells that are housed in the internal space of the battery pack case and aligned horizontally, each extending in a vertical direction; a foam kit assembly that is housed in the internal space of the battery pack case so as to be positioned above the plurality of battery cells and isolated from the outside; and foam that is discharged from the foam kit assembly and filled between an internal surface of the battery pack case and the foam kit assembly. The foam kit assembly comprises: a support frame that extends in the horizontal direction and is provided with one or more openings that allow liquid foam to pass through in the vertical direction; a foam kit that is placed on the support frame so as to be in contact with and pressed against a top cover of the battery pack case, the foam kit having an accommodation space formed therein that can accommodate liquid foam; and a pressure needle that protrudes from the support frame so as to penetrate the foam kit, and the foam is formed on a bottom surface of a housing of the battery pack case by the liquid foam flowing down from the accommodation space of the foam kit through a through hole of the foam kit formed by the pressure needle.

[0010] The foam kit has an upper surface that is in contact with the top cover and pressed downward, and a bottom surface that is pierced by the pressing needle.

[0011] The battery pack case includes the housing, the interior of which is open upward, and the top cover, which is attached to an opening at the top of the housing so as to press the foam kit of the foam kit assembly downward.

[0012] The foam is formed in a solid phase by expanding and curing a liquid foam, and is characterized in that it envelops each of the plurality of battery cells and uniformly fills gaps between the plurality of battery cells in the vertical direction.

[0013] The support frame is characterized in that it supports the shape of the upper part of the foam formed between the plurality of battery cells by being discharged from the through-hole of the foam kit, and the support frame has an edge member extending along an inner periphery of the opening of the upper part of the housing, and is disposed inside the edge member to place the foam kit thereon, is extended in the horizontal direction, is supported by the edge member, and the one or more openings are formed in a lattice shape. Crosspiece The present invention includes a component.

[0014] The pressing needle is Crosspiece The foam kit protrudes upward from multiple positions on the top surface of the component, the bottom surface of the foam kit is pierced by the pressure needle, and a gap is formed between the pierced point of the foam kit and the outer peripheral surface of the pressure needle to allow liquid foam to flow down.

[0015] The battery cells are divided into a plurality of groups according to their horizontal positions, and the pressure pins are arranged in a plurality of groups at the center positions of each of the groups so that they can be aligned in the vertical direction and are spaced apart from each other in the horizontal direction.

[0016] The foam kit comprises a pouch-shaped vinyl membrane and at least one storage chamber formed inside the pouch-shaped vinyl membrane to contain a liquid foam, and the liquid foam is a one-component liquid foam.

[0017] The foam kit comprises a pouch-shaped vinyl membrane, a plurality of storage chambers formed inside the pouch-shaped vinyl membrane to contain liquid foam, and a separation membrane disposed inside the pouch-shaped vinyl membrane to separate the plurality of storage chambers and capable of being ruptured by pressure applied from the top cover to the pouch-shaped vinyl membrane, the liquid foam being a two-component liquid foam, and the main agent and hardener of the two-component liquid foam can be contained in each of the plurality of storage chambers.

[0018] The pouch-shaped vinyl film is characterized in that it is meltable at the exothermic temperature generated during foaming and curing of the liquid foam.

[0019] A manufacturing method for a battery pack with a foam kit assembly according to an embodiment of the present invention includes a battery cell storing step of storing a plurality of battery cells arranged horizontally and each extending in the vertical direction in a housing whose interior is open upward; a foam kit assembly placing step of placing a foam kit assembly having liquid foam stored therein on the plurality of battery cells; a battery pack case assembling step of assembling a battery pack case by attaching a top cover to an opening at the top of the housing; a liquid foam spreading step of pressing the foam kit assembly against the top cover while contacting it to penetrate a portion of the foam kit assembly and diffusing the liquid foam from inside the foam kit assembly to the entire internal space of the battery pack case; and a foam forming step of foaming and hardening the liquid foam to form a foam between an internal surface of the battery pack case and the foam kit assembly.

[0020] The foam kit assembly positioning step includes a support frame placing step of placing a support frame of the foam kit assembly on the plurality of battery cells, a foam kit placing step of placing a foam kit of the foam kit assembly on the support frame, and a pressure needle contact step of bringing a pressure needle of the foam kit assembly protruding from the support frame into contact with the foam kit.

[0021] The liquid foam spreading step includes a foam kit pressing step of pressing the foam kit downward with the top cover, a discharge hole forming step of penetrating the pressing needle into the bottom surface of the foam kit to form a discharge hole, and a liquid foam discharging step of discharging the liquid foam contained inside the foam kit onto the multiple battery cells through a gap between the discharge hole and the outer peripheral surface of the pressing needle.

[0022] The liquid foam spreading step includes a liquid foam spreading step of spreading the liquid foam on the plurality of battery cells in a horizontal direction, and a liquid foam flowing step of directing a falling flow of the liquid foam from the top to the bottom of each of the plurality of battery cells.

[0023] The foam forming step is characterized by including a liquid foam solidification step in which the liquid foam is foamed, hardened and solidified, and a foam kit exterior melting step in which a pouch-shaped vinyl film forming the exterior of the foam kit is melted by heat generated by the foaming and hardening of the liquid foam.

[0024] The battery cells may be cylindrical secondary batteries, and the foam formed in the foam forming step may uniformly fill gaps between the battery cells in a vertical direction. Effect of the Invention

[0025] According to an embodiment of the present invention, when manufacturing a battery pack, a foam kit assembly is placed inside a battery pack case, the battery pack case is assembled, and foam is uniformly filled inside the battery pack case using the foam kit assembly. Therefore, the uniformity of the foam inside the battery pack case can be ensured, and the time required for manufacturing the battery pack can be reduced. [Brief description of the drawings]

[0026] [Figure 1] FIG. 2 is an exploded perspective view of a foam kit assembly and a battery pack including the foam kit assembly according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view of a support frame and a pressing needle according to an embodiment of the present invention. [Diagram 3] FIG. 2 is an exploded perspective view of a foam kit assembly according to an embodiment of the present invention. [Figure 4] FIG. 1 is a schematic diagram of a foam kit according to a modified embodiment of the present invention. [Diagram 5] 1 is a diagram illustrating a liquid foam spreading step and a foam forming step in a manufacturing method of a battery pack with a foam kit assembly according to an embodiment of the present invention. FIG. [Figure 6] FIG. 2 is a diagram for explaining a foam forming step according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] Hereinafter, the embodiments of the present invention will be described in more detail with reference to the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, and may be embodied in various different forms. The embodiments of the present invention are merely provided to complete the disclosure of the present invention and to fully inform those skilled in the art of the scope of the invention. In order to explain the embodiments of the present invention, the drawings may be exaggerated, and parts that are not related to the description may be omitted from the drawings, and the same reference numerals in the drawings indicate the same components.

[0028] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0029] 1. Battery pack with foam kit assembly according to an embodiment of the present invention

[0030] Fig. 1 is an exploded perspective view of a foam kit assembly and a battery pack including the foam kit assembly according to an embodiment of the present invention. Fig. 2 is a plan view of a support frame and a pressing needle according to an embodiment of the present invention. Fig. 3 is an exploded perspective view of the foam kit assembly according to an embodiment of the present invention.

[0031] A battery pack with a foam kit assembly according to an embodiment of the present invention will be described with reference to FIGS. 1 to 3. FIG.

[0032] A battery pack according to an embodiment of the present invention may include a battery pack case 100, a plurality of battery cells 200, a foam kit assembly 300, and a foam f.

[0033] 1.1. Battery pack case 100

[0034] The battery pack case 100 has an internal space formed so as to accommodate a plurality of battery cells 200. The battery pack case 100 may be a square cylinder. Needless to say, the shape of the battery pack case 100 may be various. The battery cells 200, the foam kit assembly 300, and the foam f may be housed inside the battery pack case 100. At this time, the battery cells 200 may be located below the foam kit assembly 300. The foam f may be formed to enclose each of the battery cells 200 while enclosing the entire battery cells 200. In particular, the foam f may be formed to fill the space between the battery cells 200 and the inner surface of the battery pack case 100 and to fill the gaps S between the battery cells 200.

[0035] The battery pack case 100 may include a housing 110 whose interior is open upward, and a top cover 120 attached to an opening at the top of the housing 110 so that the foam kit assembly 300 can be pressed downward.

[0036] The housing 110 may include a plate-shaped lower plate 111 having a predetermined area on which multiple battery cells 200 can be placed, and a square cylindrical upper frame 112 extending around the lower plate 111 and having a predetermined height, for example, a predetermined height higher than the multiple battery cells 200.

[0037] The top cover 120 may extend horizontally and may be formed with a predetermined area so that it can be placed on the upper end of the upper frame 112 .

[0038] 1.2. A plurality of battery cells 200

[0039] The multiple battery cells 200 may be housed and arranged in a horizontal direction in the internal space of the battery pack case 100. Each of the multiple battery cells 200 may be a cylindrical secondary battery cell extending in the vertical direction.

[0040] The secondary battery cell may be provided in a form in which an electrode assembly in which a positive electrode plate having a positive electrode tab attached thereto and a negative electrode plate having a negative electrode tab attached thereto are interposed with a separator between them and the positive electrode plate, the separator and the negative electrode plate are wound in a jelly roll shape and housed inside a cell case. The secondary battery cell may be provided with electrode terminals on one side and the other side opposite to the one side. In this case, if a positive electrode terminal is formed on one side of the secondary battery cell, a negative electrode terminal may be formed on the other side opposite to the one side.

[0041] For example, the battery cells 200 may be arranged in a row direction and a column direction, and the battery cells arranged in the row direction may be arranged so that the positive and negative terminals of the battery cells are alternately arranged facing upward, and the battery cells arranged in the column direction may be arranged so that the same electrode terminal faces upward, and may be stored in the internal space of the battery pack case 100. The battery cells 200 may be connected in series in the row direction by a bus bar (not shown), and may be connected in parallel in the column direction. Needless to say, the structure in which the battery cells 200 are arranged and the connection method thereof may be various. Meanwhile, the row direction may be referred to as the left-right direction, and the column direction may be referred to as the front-rear direction. The left-right direction and the front-rear direction may be collectively referred to as the horizontal direction. The direction intersecting the horizontal direction may be referred to as the up-down direction.

[0042] 1.3. Foam Kit Assembly 300

[0043] The foam kit assembly 300 is housed in the internal space of the battery pack case 100 so as to be located above the plurality of battery cells 200 and isolated from the outside. The foam kit assembly 300 may be partially penetrated by being pressed against the battery pack case 100 through contact therewith. In this case, the penetrated portion of the foam kit assembly 300 can be used as a passage for discharging liquid foam during the manufacture of a battery pack, which will be described later. That is, the foam kit assembly 300 serves to supply liquid foam to the internal space of the battery pack case 100.

[0044] 1.4. Foam Kit Assembly 300 Construction Details

[0045] The foam kit assembly 300 may include a support frame 310 , a foam kit 320 , and a pressure needle 330 .

[0046] 1.4.1. Support Frame 310

[0047] The support frame 310 may be disposed on the plurality of battery cells 200. The support frame 310 may extend in a horizontal direction. The support frame 310 may have a foam kit 320 placed on an upper surface thereof. The support frame 310 may be provided with one or more openings that allow the foam to pass through in the vertical direction.

[0048] The support frame 310 has one or more openings formed in a lattice pattern. Crosspiece A member 311; Crosspiece The member 311 may include an edge member 312 for supporting the peripheral edge of the member 311 , and a locking member 313 for placing the edge member 312 on the upper end of the upper frame 112 of the housing 110 .

[0049] Crosspiece The member 311 may have a predetermined area onto which the foam kit 320 may be placed. CrosspieceThe member 311 may be disposed inside the edge member 312, may extend horizontally, or may be supported by the lower portion of the edge member 312. Crosspiece The member 311 may have one or more openings formed in a lattice pattern. For example, Crosspiece The member 311 is a first member extending in the left-right direction. Crosspiece and a plurality of second ribs extending in the front-rear direction. Crosspiece In this case, the first Crosspiece and multiple second Crosspiece may be arranged in a lattice and connected to each other.

[0050] The edge member 312 extends along the inner periphery of the opening at the top of the housing 110. The edge member 312 may be formed, for example, in a rectangular frame shape. The edge member 312 may fit into the opening at the top of the housing 110, or may contact the inner surface of the opening at the top of the housing 110.

[0051] The locking member 313 may be formed by bending the upper end of the edge member 312 outward. That is, the locking member 313 may be in the shape of a square ring. The lower surface of the locking member 313 may be placed on the upper end of the upper frame 112 of the housing 110. The top cover 120 may be placed on the upper surface of the locking member 313.

[0052] Needless to say, the locking member 313 may be fitted into the opening at the top of the housing 110. In this case, the edge member 312 may be separated from the inner surface of the opening at the top of the housing 110 within the opening at the top of the housing 110, and the top cover 120 may be placed on the upper end of the upper frame 112 of the housing 110.

[0053] 1.4.2. Foam Kit 320

[0054] The foam kit 320 is placed on the support frame 310 so as to be in contact with the top cover 120 and be able to press downward, and a storage space capable of storing liquid foam is formed inside. That is, the foam kit 320 temporarily stores liquid foam inside, and plays a role in spraying the liquid foam inside into the internal space of the battery pack case 100 during the manufacture of the battery pack.

[0055] The thickness t2 of the foam kit 320 in the vertical direction may be greater than the thickness t1 of the edge member 312 in the vertical direction. This allows the foam kit 320 to come into contact with the lower surface of the top cover 120 and be pressed downward when the top cover 120 is assembled to the opening at the top of the housing 110.

[0056] On the other hand, the thickness t2 in the vertical direction of the foam kit 320 may be equal to the thickness t1 in the vertical direction of the edge member 312. In this case, the foam kit 320 may be placed on the pressing needle 330 and protrude a predetermined height above the edge member 312, and when the top cover 120 is assembled to the opening at the top of the housing 110, the foam kit 320 may come into contact with the lower surface of the top cover 120 and be pressed downward.

[0057] On the other hand, if the vertical thickness t2 of the foam kit 320 is smaller than the vertical thickness t1 of the edge member 312, the protruding height of the pressing needle 330 may be determined so that the foam kit 320 can protrude a predetermined height above the edge member 312 when placed on the pressing needle 330.

[0058] The foam kit 320, in the embodiment of the present invention, enables the battery pack case 100 to not have a port for injecting liquid foam, thereby simplifying the structure of the battery pack case 100. Also, the foam kit 320, in the embodiment of the present invention, moves the liquid foam inside the battery pack case 100, thereby simplifying the manufacturing steps of the battery pack, and does not require a device for forcibly injecting the liquid foam from the outside to the inside of the battery pack case 100, thereby simplifying the manufacturing equipment for the battery pack.

[0059] The foam kit 320 may include a pouch-shaped vinyl membrane 321 and at least one reservoir 322 formed within the pouch-shaped vinyl membrane 321 to contain the liquid foam.

[0060] The liquid foam may be a one-component liquid foam, or may contain a wide variety of substances capable of foaming and hardening upon contact with air. The liquid foam can be kept in a liquid state while being contained inside the storage chamber 322 and prevented from contacting with air by the pouch-shaped vinyl film 321. The liquid foam may foam and harden upon contact with air while flowing out into the internal space of the battery pack case 100 upon rupture of the pouch-shaped vinyl film 321. At this time, a predetermined amount of heat may be generated.

[0061] The pouch-shaped vinyl film 321 is CrosspieceThe pouch-shaped vinyl film 321 may be disposed on the member 311. The pouch-shaped vinyl film 321 serves to temporarily store the liquid foam therein, and when a portion of the pouch-shaped vinyl film 321 is broken by the pressing needle 330, the pouch-shaped vinyl film 321 serves to discharge the liquid foam therein into the internal space of the battery pack case 100. Meanwhile, the pouch-shaped vinyl film 321 may contain a predetermined material that allows it to melt at a heat generation temperature during foaming and hardening of the liquid foam, and may have a predetermined thickness. Therefore, when foaming and hardening of the liquid foam are completed to form foam f, at least a portion of the pouch-shaped vinyl film 321 can be melted and removed by heat.

[0062] 1.4.3. Pressing needle 330

[0063] The pressing needle 330 protrudes from the support frame 310 so as to penetrate the foam kit 320. Specifically, the pressing needle 330 is Crosspiece The pressing needle 330 protrudes upward from a plurality of positions on the upper surface of the member 311, so that the bottom surface of the foam kit 320 can be penetrated by the pressing needle 330 when assembling the battery pack case 100. The pressing needle 330 may be formed in a cone shape. Needless to say, the shape of the pressing needle 330 may be various.

[0064] Meanwhile, a gap may be formed between the outer surface of the pressing needle 330 and the pierced portion of the foam kit 320 to allow the liquid foam to flow downward, and the liquid foam inside the foam kit 320 can flow downward through this gap.

[0065] Meanwhile, the battery cells 200 may be divided into a plurality of groups according to their positions in the horizontal direction. Also, a plurality of pressing needles 330 may be provided at the center positions of the plurality of groups so as to be vertically aligned and spaced apart from each other in the horizontal direction. This allows the above-mentioned gaps through which the liquid foam can flow down to be uniformly spaced apart from each other in the horizontal direction, and the liquid foam can be uniformly supplied onto the battery cells 200 during the manufacture of the battery pack.

[0066] 1.5. Form F

[0067] The foam f is discharged from the foam kit assembly 300 and filled between the inner surface of the battery pack case 100 and the foam kit assembly 300. At this time, the foam f may be discharged downward from the portion of the foam kit 320 pierced by the pressing needle 330 of the foam kit assembly 300, and uniformly fill the gaps S between the multiple battery cells 200 in the vertical direction. That is, the foam f is discharged from the pierced portion of the foam kit 320, and is formed in a solid phase by foaming and hardening of the liquid foam, and envelops each of the multiple battery cells 200.

[0068] 1.6. Foam kit according to variant 1 of the present invention

[0069] FIG. 4 is a schematic diagram of a foam kit according to the first modified example of the present invention.

[0070] Referring to Figure 4, a foam kit 320' according to variant example 1 of the present invention comprises a pouch-shaped vinyl membrane 321, a plurality of storage chambers 322a, 322b formed inside the pouch-shaped vinyl membrane 321 so as to contain liquid foam, and a separation membrane 323 disposed inside the pouch-shaped vinyl membrane 321 so as to separate the plurality of storage chambers 322a, 322b and which can be ruptured by pressure applied from the top cover 120 to the pouch-shaped vinyl membrane 321.

[0071] In this case, the liquid foam may be a two-component liquid foam. That is, the liquid foam may contain a base agent and a curing agent. In this case, the base agent and the curing agent must be separated from each other and mixed when forming the foam f. Therefore, a plurality of storage chambers 322a, 322b are provided inside the pouch-shaped vinyl film 321, and the base agent and the curing agent of the two-component liquid foam may be stored in the plurality of storage chambers, respectively, and may be mixed with each other when the separation membrane 323 breaks during assembly of the battery pack case 100. On the other hand, the separation membrane 323 may be formed to a predetermined thickness that makes it easier to break than the pouch-shaped vinyl film 321, and may break before the pouch-shaped vinyl film 321 is penetrated by the pressing needle 330 when the pouch-shaped vinyl film 321 is pressed by the top cover 120.

[0072] 1.7. Battery pack case according to modification 2 of the present invention

[0073] Meanwhile, the foam kit 320 is pierced by the pressing needle 330, and the liquid foam flows down into the gap therebetween. At this time, the liquid foam flows down from the upper part to the lower part of the battery cell. At this time, the air near the lower part of the battery cell cannot escape to the upper side of the liquid foam, and may be isolated at the lower part of the battery pack case 100 by the liquid foam. In addition, when the liquid foam is solidified while foaming and curing, it may release a certain gas, and the released gas may accumulate at the lower part of the battery pack case 100.

[0074] In order to allow the air and gas to move smoothly to the upper portion of the battery pack case 100, the housing 110 of the battery pack case according to the second modified example of the present invention may be provided with a predetermined air pressure adjustment hole (not shown).

[0075] Specifically, the housing 110 may include a lower plate 111 having an area on which a plurality of battery cells 200 can be placed, and an upper frame 112 extending along the periphery of the lower plate 111 and having a height higher than the plurality of battery cells 200. Here, the air pressure adjustment hole may extend inside the lower plate 111 and inside the upper frame 112, with an inlet formed on the upper surface of the lower plate 111 and an outlet formed on the inner circumferential surface of the upper end of the upper frame 112 or the outer circumferential surface of the upper end of the upper frame 112. At least one such air pressure adjustment hole may be formed.

[0076] The air pressure adjustment hole can prevent air or gas from being isolated at the bottom of the battery pack case 100, and therefore allows the liquid foam to smoothly flow down to the top surface of the lower plate 111.

[0077] 2. Method for manufacturing a battery pack with a foam kit assembly according to an embodiment of the present invention

[0078] Fig. 5 is a diagram for explaining a liquid foam spreading step and a foam forming step in the manufacturing method of a battery pack with a foam kit assembly according to an embodiment of the present invention. Fig. 6 is a diagram for explaining the foam forming step according to an embodiment of the present invention.

[0079] A method for manufacturing a battery pack with a foam kit assembly according to an embodiment of the present invention will be described with reference to Figures 1 to 6. In describing the method for manufacturing a battery pack with a foam kit assembly, details that overlap with the above description of the battery pack with a foam kit assembly according to an embodiment of the present invention will be omitted or will be described briefly.

[0080] A method for manufacturing a battery pack with a foam kit assembly according to an embodiment of the present invention may include the following steps.

[0081] 2.1. Battery cell storage steps

[0082] In the battery cell storing step, a task is performed of storing a plurality of battery cells 200, each of which is arranged horizontally and extends vertically, in the housing 110 whose interior is open upward. Each of the plurality of battery cells 200 may be a cylindrical secondary battery. The plurality of battery cells 200 may be electrically connected to each other by a bus bar (not shown). The plurality of battery cells 200 may be spaced apart from each other by a predetermined distance to form a gap S between them.

[0083] 2.2. Foam Kit Assembly Placement Steps

[0084] In the foam kit assembly placement step, a foam kit assembly 300 containing liquid foam therein is placed on top of a plurality of battery cells 200.

[0085] The foam kit assembly arrangement step may include a support frame placement step of placing the support frame 310 of the foam kit assembly 300 on the plurality of battery cells 200, a foam kit placement step of placing the foam kit 320 of the foam kit assembly 300 on the support frame 310, and a press needle contact step of bringing the press needles 330 of the foam kit assembly 300 protruding from the support frame 310 into contact with the foam kit 320. In this step, since no pressure is applied to the foam kit 320 by the top cover 120, the foam kit 320 may be placed on the press needles 330.

[0086] 2.3. Battery pack case assembly steps

[0087] In the battery pack case assembling step, the top cover 120 is attached to the opening at the top of the housing 110 to assemble the battery pack case.

[0088] For example, in a structure in which the locking member 313 of the support frame 310 is placed around the opening at the top of the housing 110, the top cover 120 may be placed and attached on the upper surface of the locking member 313. In a structure in which the locking member 313 of the support frame 310 is fitted into the opening at the top of the housing 110, the top cover 120 may be placed and attached on the upper end of the upper frame 112 of the housing 110. The liquid foam diffusion step may be performed simultaneously while performing the battery pack case assembling step. That is, in the embodiment of the present invention, the liquid foam diffusion step can be performed quickly by assembling the battery pack case 100, thereby shortening the entire manufacturing process of the battery pack.

[0089] 2.4. Liquid foam diffusion step

[0090] In the liquid foam spreading step, foam kit 320 of foam kit assembly 300 is brought into contact with the underside of top cover 120, and foam kit 320 is pressed down to pierce a portion of foam kit 320 of foam kit assembly 300 with pressure needle 330, thereby spreading the liquid foam from inside foam kit 320 of foam kit assembly 300 throughout the entire internal space of battery pack case 100.

[0091] The liquid foam spreading step may include a foam kit pressing step of pressing the foam kit 320 downward with the top cover 120, a discharge hole forming step of penetrating the bottom surface of the foam kit 320 with the pressing needle 330 to form a discharge hole, and a liquid foam discharging step of discharging the liquid foam contained inside the foam kit 320 onto the multiple battery cells 200 through the gap between the discharge hole and the outer peripheral surface of the pressing needle 330.

[0092] That is, while the top cover 120 is attached to the housing 110 to assemble the battery pack case 100, the top cover 120 may press the foam kit 320 downward to cause the pressing needles 330 to penetrate the bottom surface of the foam kit 320. For this reason, a plurality of through holes, for example, discharge holes, may be formed in the bottom surface of the foam kit 320, and liquid foam temporarily stored inside the foam kit 320 may be smoothly discharged downward through the gap between the through holes and the pressing needles 330.

[0093] Meanwhile, the liquid foam spreading step may include a liquid foam spreading step of spreading the liquid foam on the multiple battery cells 200 in a horizontal direction, and a liquid foam flowing step of directing a falling flow F of the liquid foam from the top to the bottom of each of the multiple battery cells 200. That is, the liquid foam discharged onto the multiple battery cells 200 through the through holes has a predetermined viscosity, and before flowing down into the gaps between the multiple battery cells 200, it flows in the horizontal direction where it is easier to flow, and can be spread uniformly in the horizontal direction over the multiple battery cells 200. At this time, Crosspiece One or more lattice-shaped openings formed in the member 311 may be utilized. Then, the liquid foam may flow down from the upper portion to the lower portion of each of the plurality of battery cells 200 through the gaps S between the plurality of battery cells 200. At this time, the liquid foam may be uniformly filled in the gaps S between the plurality of battery cells 200 in the vertical direction. The foam forming step may be performed while performing the liquid foam spreading step and the liquid foam pouring step.

[0094] 2.5. Foam formation step

[0095] In the foam forming step, a liquid foam may be expanded and hardened in the internal space of the battery pack case 100 to form a solidified foam f between the internal surface of the battery pack case 100 and the foam kit assembly 300.

[0096] That is, the foam forming step may include a liquid foam solidification step of foaming and hardening the liquid foam to solidify it, and a foam kit exterior melting step of melting the pouch-shaped vinyl film 321 forming the exterior of the foam kit 320 with heat generated by foaming and hardening the liquid foam, for example, heat of about 40°C. The liquid foam may be foamed and hardened by contacting with air inside the battery pack case 100, or may be foamed and hardened by mixing a base agent and a hardener. Meanwhile, when the pouch-shaped vinyl film 321 of the foam kit 320 is melted by heat, foam f may also be formed in the space occupied by the pouch-shaped vinyl film 321. Needless to say, only a part of the pouch-shaped vinyl film 321 may be melted and removed by heat, or the entirety may remain on the support frame 310.

[0097] The foam f formed through such a foam formation step can uniformly fill the gaps S between the multiple battery cells 200 in the vertical direction, and after solidification, can block heat conduction between the multiple battery cells 200 and guide materials leaking from a failed battery cell away from other battery cells, thereby preventing short circuits from occurring between the multiple battery cells 200.

[0098] The above-mentioned embodiments of the present invention are for the purpose of explaining the present invention, and are not intended to limit the present invention. It should be noted that the configurations and methods disclosed in the above-mentioned embodiments of the present invention may be modified in various forms by combining or interchanging with each other, and these modifications may also be considered to fall within the scope of the present invention. That is, the present invention may be embodied in various different forms within the scope of the claims and the technical ideas equivalent thereto, and those skilled in the art to which the present invention pertains may understand that various embodiments are possible within the scope of the technical ideas of the present invention. [Explanation of symbols]

[0099] 100: Battery pack case 110: Housing 120: Top cover 200: Multiple battery cells 300: Foam kit assembly 310: Support frame 311: Crosspiece Materials 312: Edge material 313: Locking member 320: Foam kit 321: Pouch-shaped vinyl membrane 322:Storage room 330: Pressing needle S: Gap f:form F: Falling flow of liquid foam

Claims

1. a battery pack case having an internal space; A plurality of battery cells are housed in the internal space of the battery pack case, are arranged in a horizontal direction, and each of the battery cells extends in a vertical direction; a foam kit assembly housed in the internal space of the battery pack case to be positioned above the plurality of battery cells and isolated from the outside; a foam discharged from the foam kit assembly and filling a space between an inner surface of the battery pack case and the foam kit assembly; Equipped with The foam kit assembly comprises: a support frame extending in the horizontal direction and having one or more openings for allowing the liquid foam to pass in the vertical direction; a foam kit placed on the support frame so as to be in contact with and pressed against the top cover of the battery pack case, the foam kit having an internal storage space for storing the liquid foam; a pressure needle extending from the support frame through the foam kit; Equipped with The form may include: the liquid foam flows down from the accommodation space of the foam kit through the through hole of the foam kit formed by the pressing needle and is formed on a bottom surface of a housing of the battery pack case, the foam is a liquid foam before being filled into the gaps between the battery cells; The battery pack with foam kit assembly, wherein when the liquid foam is filled into the gaps between the plurality of battery cells, the liquid foam foams while filling the gaps between the plurality of battery cells and hardens to become the foam.

2. 2. The battery pack with foam kit assembly according to claim 1, wherein the foam kit has an upper surface in contact with the top cover and pressed downward, and a bottom surface penetrated by the pressing needle.

3. The battery pack case includes: The housing has an interior that is open upward; the top cover being attached to an opening at the top of the housing so as to be able to press the foam kit of the foam kit assembly downward; 3. The battery pack with foam kit assembly of claim 2, comprising:

4. 4. The battery pack with foam kit assembly according to claim 3, wherein the foam is formed in a solid phase by foaming and curing of the liquid foam, and uniformly fills gaps between the plurality of battery cells in the vertical direction while enveloping each of the plurality of battery cells.

5. The support frame is extruded from a through-hole of the foam kit to support a shape of an upper portion of the foam formed between the plurality of battery cells, The support frame is a rim member extending along an inner periphery of the opening in the upper portion of the housing; a crosspiece member disposed inside the edge member so as to place the foam kit thereon, extending in the horizontal direction and supported by the edge member, the crosspiece member having the one or more openings formed in a lattice pattern; 5. The battery pack with foam kit assembly of claim 4, comprising:

6. The pressing needles protrude upward from a plurality of positions on the top surface of the crosspiece member, The foam kit has a bottom surface pierced by the pressing needle, 6. The battery pack with foam kit assembly as described in claim 5, characterized in that a gap is formed between the pierced portion of the foam kit and the outer peripheral surface of the pressing needle, allowing the liquid foam to flow down.

7. The battery cells are divided into a plurality of groups according to positions in the horizontal direction, 5. The battery pack with foam kit assembly according to claim 4, wherein the pressing pins are arranged in a plurality of groups so as to be aligned in the vertical direction at the center positions of the groups, and are spaced apart from each other in the horizontal direction.

8. The foam kit comprises: A pouch-shaped vinyl film; at least one reservoir formed within said pouch-shaped vinyl membrane for containing said liquid foam; Equipped with 5. The battery pack with foam kit assembly according to claim 4, wherein the liquid foam is a one-component type liquid foam.

9. The foam kit comprises: A pouch-shaped vinyl film; a plurality of storage chambers formed within the pouch-shaped vinyl membrane for containing the liquid foam; A separation membrane is provided inside the pouch-shaped vinyl membrane so as to separate the plurality of storage chambers, and can be broken by pressure applied from the top cover to the pouch-shaped vinyl membrane. The liquid foam is a two-component liquid foam, The battery pack with foam kit assembly according to claim 4 , wherein the base material and the hardener of the two-component liquid foam can be accommodated in each of the plurality of storage chambers.

10. 10. The battery pack with foam kit assembly according to claim 8 or 9, wherein the pouch-shaped vinyl film is meltable at an exothermic temperature during foaming and curing of the liquid foam.

11. The housing includes: a lower plate having an area on which the plurality of battery cells can be mounted; an upper frame extending around the lower plate and having a height greater than the plurality of battery cells; Equipped with 4. The battery pack with foam kit assembly according to claim 3, further comprising at least one air pressure adjustment hole extending into an interior of the lower plate and an interior of the upper frame, the air pressure adjustment hole having an inlet formed on an upper surface of the lower plate and an outlet formed on an inner peripheral surface of an upper end of the upper frame or an outer peripheral surface of an upper end of the upper frame.

12. a battery cell storage step for storing a plurality of battery cells arranged horizontally in a housing whose interior is open upward and each of the battery cells extends vertically; a foam kit assembly placement step of placing a foam kit assembly having a liquid foam stored therein on the plurality of battery cells; a battery pack case assembling step of assembling a battery pack case by attaching a top cover to an opening at an upper portion of the housing; a liquid foam spreading step of pressing the foam kit assembly against the top cover while contacting the foam kit assembly to penetrate a portion of the foam kit assembly and spread the liquid foam from inside the foam kit assembly to the entire internal space of the battery pack case; a foam forming step of expanding and curing the liquid foam to form a foam between an inner surface of the battery pack case and the foam kit assembly; Including, the foam is a liquid foam before being filled into the gaps between the battery cells; a liquid foam filling the gaps between the battery cells while foaming when the liquid foam is filled in the gaps between the battery cells and hardening to become the foam.

13. The foam kit assembly placement step includes: a support frame placing step of placing a support frame of the foam kit assembly on the plurality of battery cells; a foam kit mounting step of mounting a foam kit of the foam kit assembly on the support frame; a pressing needle contacting step of bringing a pressing needle of the foam kit assembly protruding from the support frame into contact with the foam kit; The method for manufacturing a battery pack with a foam kit assembly according to claim 12, comprising:

14. The liquid foam spreading step includes: a foam kit pressing step of pressing the foam kit downward with the top cover; a discharge hole forming step of penetrating the pressing needle through the bottom surface of the foam kit to form a discharge hole; a liquid foam discharging step of discharging the liquid foam contained inside the foam kit onto the plurality of battery cells through a gap between the discharge hole and an outer circumferential surface of the pressing needle; The method for manufacturing a battery pack with a foam kit assembly according to claim 13, comprising:

15. The liquid foam spreading step includes: a liquid foam spreading step of horizontally spreading the liquid foam on the plurality of battery cells; a liquid foam flowing step of directing a falling flow of the liquid foam from the upper portion to the lower portion of each of the plurality of battery cells; The method for manufacturing a battery pack with a foam kit assembly according to claim 14, comprising:

16. The foam forming step comprises: A liquid foam solidification step in which the liquid foam is expanded, cured, and solidified; a foam kit exterior melting step of melting the pouch-shaped vinyl film forming the exterior of the foam kit by heat generated by foaming and curing of the liquid foam; The method for manufacturing a battery pack with a foam kit assembly according to claim 14, comprising:

17. the battery cell is a cylindrical secondary battery, 16. The method of manufacturing a battery pack with a foam kit assembly according to claim 15, wherein the foam formed in the foam forming step uniformly fills gaps between the plurality of battery cells in a vertical direction.

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