Battery module, battery pack, automobile, and method for manufacturing battery module

Abstract

A battery module according to an embodiment of the present disclosure may include at least one battery cell and a module housing. The module housing includes a first frame including a main body and a first extension extending in at least one direction from both ends of the main body to form an accommodation space for accommodating the at least one battery cell, a second frame including a cover portion facing the main body and covering the accommodation space and a second extension portion extending in at least one direction from both ends of the cover portion and positioned to face each of the first extension portions, and a coupling plate including a first portion coupled to the first extension portion and a second portion coupled to the second extension portion, the first portion being spaced apart from an end of the first frame in the extension direction.

Description

[Technical Field]

[0001] This application claims the benefit of priority based on Korean Patent Application No. 10-2021-0128158, filed on September 28, 2021, and all contents disclosed in the documents of this Korean patent application are incorporated herein by reference.

[0002] The present disclosure relates to a battery module, a battery pack, an automobile, and a method for manufacturing a battery module, and more particularly to a battery module that reduces the manufacturing cost of a module housing and improves durability, a battery pack including the battery module, an automobile, and a method for manufacturing a battery module. [Background technology]

[0003] Currently, commercially available secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, and lithium secondary batteries. Lithium secondary batteries have almost no memory effect compared to nickel-based secondary batteries and can be charged and discharged freely. Lithium secondary batteries are also attracting attention due to their extremely low self-discharge rate and high energy density.

[0004] Lithium secondary batteries mainly use lithium-based oxides and carbon materials as the positive and negative electrode active materials, respectively, and include an electrode assembly in which a separator is sandwiched between positive and negative electrode plates coated with the positive and negative electrode active materials, and an exterior material that hermetically houses the electrode assembly together with an electrolyte.

[0005] Generally, lithium secondary batteries are divided into can-type secondary batteries and pouch-type secondary batteries depending on the type of exterior material. Can-type secondary batteries have an electrode assembly built into a metal can. Pouch-type secondary batteries have an electrode assembly built into a pouch made of an aluminum laminate sheet.

[0006] Recently, secondary batteries have been widely used not only in small devices such as portable electronic devices but also in medium-sized and large devices such as automobiles and power storage devices. At least one battery module is installed in such medium-sized and large devices. To increase the capacity and output of such a battery module, multiple battery cells may be housed inside a module housing. For example, pouch-type secondary battery cells, which are easy to stack, are often used in such medium-sized and large devices. Here, a pouch-type battery cell refers to a secondary battery in which an electrode assembly is housed in a pouch made of an irregularly shaped flexible polymer material.

[0007] FIG. 1 is a perspective view that schematically shows the state of a module housing of a battery module of the prior art.

[0008] The conventional module housing 20 may have an accommodation space capable of accommodating a plurality of battery cells (not shown) therein. The module housing 20 may be manufactured by coupling an upper cover 21 and a lower frame 22 to each other. Here, both ends of the upper cover 21 in the left-right direction (X-axis direction) and the upper cross section of the lower frame 22 may be coupled to each other at corners D. When swelling (volume expansion) occurs in the battery cells accommodated inside the module housing 20 during charging and discharging of the battery module, the module housing 20 may experience a problem in which stress is easily concentrated at the corners D of the module housing 20, which are the coupling portions between the upper cover 21 and the lower frame 22, due to the pressure caused by the swelling of the battery cells. Therefore, the conventional battery module has a problem in which the corners D, which are the coupling portions between the upper cover 21 and the lower frame 22, are easily damaged or separated.

[0009] Furthermore, in the conventional battery module, if the thickness of the lower frame 22 is excessively increased in order to increase the bonding strength between the upper cover 21 and the lower frame 22, there are problems in that the material cost of the lower frame 22 increases and the weight of the battery module increases. In particular, when multiple battery modules are installed, such as in an electric vehicle, the weight of the battery modules must not increase in order to reduce the vehicle weight. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Korean Patent Application Publication No. 10-2019-0127056 [Patent Document 2] Japanese Patent Application Laid-Open No. 2015-111493 [Patent Document 3] Korean Patent Application Publication No. 10-2017-0030954 [Patent Document 4] Korean Patent Application Publication No. 10-2019-0138072 Summary of the Invention [Problem to be solved by the invention]

[0011] The present disclosure provides a battery module, a battery pack, a vehicle, and a method for manufacturing a battery module that reduces the manufacturing cost of a module housing and improves durability. [Means for solving the problem]

[0012] According to one embodiment of the present disclosure, a battery module includes at least one battery cell and a module housing. The module housing includes a first frame including a main body and first extensions extending in at least one direction from both ends of the main body to form an accommodation space for accommodating the at least one battery cell, a second frame including a cover that faces the main body and covers the accommodation space and second extensions that extend in at least one direction from both ends of the cover and are positioned to face the first extensions, and a coupling plate that is spaced apart from an end of the first extension of the first frame in the extension direction and includes a first portion coupled to the first extension and a second portion coupled to the second extension.

[0013] In one embodiment, the first portion and the second portion are arranged on different planes, the first portion of the coupling plate is arranged on an outer surface of the first extension portion, the inner surface of the second extension portion faces the outer surface of the first extension portion and is arranged closer to the cover portion than the first portion, and an end portion of the second extension portion in the extension direction can be coupled to the second portion of the coupling plate.

[0014] In one embodiment, the first portion and the second portion are arranged on different planes, the first portion of the coupling plate is arranged on an inner surface of the first extension portion of the first frame, the outer surface of the second extension portion faces the inner surface of the first extension portion and is arranged closer to the cover portion than the first portion, and an end portion of the second extension portion in the extension direction can be coupled to the second portion of the coupling plate.

[0015] In one embodiment, the first portion may contact the first extension portion on a broad surface of the plate-like surface of the coupling plate, and the second portion may contact an opposite end of the second extension portion.

[0016] In one embodiment, the second extension portion of the second frame may have a coupling groove formed therein that is recessed from an end of the extension direction in a direction opposite to the extension direction, and the coupling plate may include a protruding insertion portion at the second portion that protrudes from an end of the coupling plate to be inserted into the coupling groove.

[0017] In another embodiment, the protruding insert may include a wedge-shaped protrusion protruding from an end of the protruding insert to press against the inner surface of the coupling groove.

[0018] In yet another embodiment, a first inclined surface may be formed on a portion of the second extension portion that is coupled to the second portion of the coupling plate, and a second inclined surface parallel to the first inclined surface may be formed on the second portion of the coupling plate that is coupled to the second extension portion.

[0019] In yet another embodiment, the first inclined surface may have a shape in which the height of the inclined surface continuously decreases toward the inside of the battery module, and the second inclined surface may have a shape in which the height of the inclined surface continuously increases toward the outside of the battery module.

[0020] According to yet another aspect of the present disclosure, the first portion is a plate-shaped wide surface of the coupling plate, the second portion faces and contacts an end of the second extension portion, and the coupling plate may further include a stopper extending from the second portion to surround the second extension portion.

[0021] The coupling plate may be elongated in a direction parallel to the first and second extensions.

[0022] Meanwhile, according to one embodiment of the present disclosure, a battery pack includes at least one battery module.

[0023] Meanwhile, according to one embodiment of the present disclosure, a vehicle includes at least one battery module.

[0024] Meanwhile, according to one embodiment of the present disclosure, a method for manufacturing a battery module includes the steps of: preparing at least one battery cell; preparing a first frame having an accommodation space for accommodating the at least one battery cell, the first frame including a main body portion and first extension portions extending in at least one direction from both ends of the main body portion; mounting the at least one battery cell in the accommodation space of the first frame; preparing a second frame including a cover portion facing the main body portion and covering the accommodation space, and second extension portions extending in at least one direction from both ends of the cover portion and configured to face each of the first extension portions; coupling a plurality of coupling plates to an outer surface of the first extension portion of the first frame so as to be spaced apart in a direction away from an end of the first extension portion in the extension direction - the coupling plate including a first portion which is a plate-shaped wide surface that couples to the outside of the first extension portion and a second portion that couples to an end of the second extension portion - and coupling the second portion to the second extension portion.

[0025] In one embodiment, the first portion and the outer side of the first extension are joined by welding, the second portion and the end of the second extension are joined by welding, and at least two of the joining plate, the first extension, and the second extension can be made of the same material. [Effects of the Invention]

[0026] The battery module of the present disclosure includes a connecting plate configured to connect to each of the first extension portion of the first frame and the second extension portion of the second frame. Compared to a structure in which the upper cover and lower frame are directly connected, such as the module housing of the prior art battery module of Figure 1, there is no need to increase the thickness of the first frame or the second frame to increase the connecting area of ​​the first frame or the second frame of the module housing, which reduces manufacturing costs and enables the battery module to be made lighter.

[0027] Furthermore, the battery module of the present disclosure includes a connecting plate spaced apart in a direction away from the end of the extension direction of the first extension portion of the first frame. Compared to the structure in which the ends (corner portions) of the upper cover and lower frame of the module housing of the prior art shown in FIG. 1 are connected to each other, even if swelling (volume expansion) of the battery cells housed inside the module housing occurs, the risk of damage or separation between the connecting plate and the second extension portion of the second frame due to the pressure caused by the swelling can be relatively reduced. [Brief explanation of the drawings]

[0028] [Figure 1] FIG. 1 is a perspective view schematically illustrating a module housing of a battery module according to a related art. [Figure 2] 1 is a perspective view schematically illustrating a battery module according to an embodiment of the present disclosure. [Figure 3] 1 is an exploded perspective view schematically illustrating a battery module according to an embodiment of the present disclosure. [Figure 4] FIG. 2 is a partial front view schematically illustrating a portion of a module housing of a battery module according to an embodiment of the present disclosure. [Figure 5] FIG. 10 is a perspective view schematically illustrating a battery module according to another embodiment of the present disclosure. [Figure 6] FIG. 10 is a partial front view schematically illustrating a portion of a module housing of a battery module according to another embodiment of the present disclosure. [Figure 7] FIG. 2 is a partial perspective view schematically illustrating a part of a second frame of a battery module according to an embodiment of the present disclosure. [Figure 8] 1 is a perspective view schematically illustrating a first frame and a joining plate of a battery module according to an embodiment of the present disclosure. FIG. [Figure 9] 1 is a partial perspective view schematically illustrating a portion of a first frame and a joining plate of a battery module according to an embodiment of the present disclosure. FIG. [Figure 10]FIG. 10 is a partial side view schematically illustrating a portion of a second frame and a joining plate of a battery module according to another embodiment of the present disclosure. [Figure 11] FIG. 10 is a partial front view schematically illustrating a portion of a module housing of a battery module according to another embodiment of the present disclosure. [Figure 12] FIG. 10 is a partial front view schematically illustrating a portion of a module housing of a battery module according to still another embodiment of the present disclosure. [Figure 13] 1 is a perspective view schematically illustrating a battery pack according to an embodiment of the present disclosure. [Figure 14] 1 is a schematic diagram illustrating an automobile according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0029] The present disclosure will be described in detail below with reference to the drawings. When describing the present disclosure, if it is determined that a detailed description of related known functions or configurations may obscure the gist of the present disclosure, the detailed description thereof will be omitted. Furthermore, the following embodiments may be modified into various other forms, and the scope of the technical idea of ​​the present disclosure is not limited to the following embodiments. Rather, these embodiments are provided to make the present disclosure more complete and complete, and to fully convey the technical idea of ​​the present disclosure to those skilled in the art.

[0030] It should be understood that the technology described in this disclosure is not limited to a particular embodiment, but includes various modifications, equivalents, and / or alternatives of the embodiments of the present disclosure.

[0031] In connection with the description of the drawings, like reference numerals may be used for like components.

[0032] In this disclosure, the terms "have," "can have," "include," or "can include" indicate the presence of a given feature (e.g., a value, a function, an operation, or a component such as a part) and do not exclude the presence of additional features.

[0033] In this disclosure, phrases such as "A or B," "at least one of A and / or B," or "one or more of A and / or B" include all possible combinations of the items listed together. For example, "A or B," "at least one of A and B," or "at least one of A or B" can refer to (1) at least one A, (2) at least one B, or (3) both at least one A and at least one B.

[0034] Fig. 2 is a perspective view schematically illustrating the appearance of a battery module 100 according to an embodiment of the present disclosure. Fig. 3 is an exploded perspective view schematically illustrating the appearance of a battery module 100 according to an embodiment of the present disclosure. Fig. 4 is a partial front view schematically illustrating the appearance of a portion of a module housing 120 of a battery module 100 according to an embodiment of the present disclosure. For reference, the X-axis direction shown in Fig. 2 is rightward, the Y-axis direction is rearward, and the Z-axis direction is upward.

[0035] 2 to 4, a battery module 100 according to an embodiment of the present disclosure includes at least one battery cell 110 and a module housing 120. As shown in FIG.

[0036] Specifically, the battery cell 110 may be, for example, a secondary battery having a pouch-type case made of a flexible material. However, the battery cell 110 is not necessarily limited to this type of battery, and may be a prismatic or cylindrical battery. The pouch-type case may include at least one laminate sheet. The laminate sheet may have a structure in which a thin metal film (e.g., an Al film) is laminated between a water-resistant polymer film (e.g., nylon) and a thermally adhesive polymer film (e.g., cast polypropylene). The structure of the laminate sheet and the materials constituting each layer are well known in the technical field to which the present disclosure pertains, and therefore, detailed description thereof will be omitted.

[0037] The battery cell 110 also includes an electrode assembly assembled in a stacked form, including a positive electrode plate coated with a positive electrode active material, a negative electrode plate coated with a negative electrode active material, and a separator interposed between the positive electrode plate and the negative electrode plate, and a battery case (pouch-type case) that hermetically stores the electrode assembly together with an electrolyte.

[0038] Furthermore, the battery cell 110 may be provided with electrode leads 111 at, for example, the front and rear ends thereof. The electrode leads 111 are divided into positive and negative leads according to their electrical polarities.

[0039] The module housing 120 may have an accommodating space for accommodating the plurality of battery cells 110 therein. The module housing 120 may include a first frame 121, a second frame 122, and a coupling plate 123. The first frame 121 may include a main body 121a and a first extension 121b. The main body 121a may have, for example, an upper portion on which the plurality of battery cells 110 are mounted. The main body 121a may have a plate shape extending widely in the horizontal direction (X-axis direction and Y-axis direction) to support the plurality of battery cells 110 upward. Each of the first extensions 121b may extend in at least one direction from each of both ends of the main body 121a. For example, as shown in FIG. 3, each of the first extensions 121b may extend upward (e.g., in the Z-axis direction) from each of the left and right ends of the main body 121a. The first frame 121 may be made of a metal material. The first frame 121 may include, for example, an aluminum alloy or stainless steel, which has excellent thermal conductivity.

[0040] The second frame 122 may include a cover portion 122a and a second extension portion 122b. More specifically, the cover portion 122a may be positioned to face the main body portion 121a in the vertical direction (e.g., the Z-axis direction). That is, the cover portion 122a may be spaced a predetermined distance from the main body portion 121a. The module housing 120 may include an accommodation space between the cover portion 122a and the main body portion 121a, in which at least one battery cell 110 may be accommodated. Each of the second extension portions 122b may extend in at least one direction, for example, the Z-direction, from each end of the cover portion 122a. The second extension portion 122b may be positioned to face each of the first extension portions 121b. For example, the second extension portion 122b may be positioned to be in close contact with the outer surface of the first extension portion 121b. The second frame 122 may be made of, for example, an aluminum alloy or stainless steel having excellent thermal conductivity.

[0041] In addition, the plurality of coupling plates 123 may be spaced apart from each other in a direction away from the end E of the first extension portion 121b of the first frame 121 in the extension direction (Z-axis direction). For example, as shown in FIG. 4, the coupling plates 123 may be spaced apart a predetermined distance downward from the upper end (Z-axis direction) of the first extension portion 121b of the first frame 121. For example, the coupling plate 123 includes a first portion coupled to the first extension portion 121b. The first portion of the coupling plate 123 may be coupled to an outer surface of the first extension portion 121b of the first frame 121. For example, as shown in FIG. 3, at least a portion (first portion) of the left or right side of the coupling plate 123 may be coupled to the outer surface of the first extension portion 121b of the first frame 121. For example, the coupling plate 123 may be joined to the outer surface of the first extension portion 121b (the outer surface in the negative or positive direction of the X-axis). The joining method may be welding. The coupling plate 123 includes a second portion coupled to the second extension 122b. The second portion may be in contact with and face an end of the second extension 122b. For example, an upper surface of the coupling plate 123 may be coupled to a lower end of the second extension 122b of the second frame 122.

[0042] The coupling plate 123 may be formed to be elongated in a direction parallel to the first extension portion 121b and the second extension portion 122b.

[0043] Therefore, according to such a configuration of the present disclosure, the battery module 100 of the present disclosure includes a connecting plate 123 configured to connect to each of the first extension portion 121b of the first frame 121 and the second extension portion 122b of the second frame 122. Compared to a structure in which the upper cover 21 and the lower frame 22 are directly connected, such as the module housing 20 of the conventional battery module of Figure 1, there is no need to increase the thickness of the first frame 121 or the second frame 122 to increase the connecting area of ​​the first frame 121 or the second frame 122 of the module housing 120, thereby reducing manufacturing costs and making the battery module 100 lighter.

[0044] Furthermore, the battery module 100 of the present disclosure includes a connecting plate 123 spaced apart in a direction away from the end of the extension direction of the first extension portion 121b of the first frame 121. Compared to the structure in which the ends of the upper cover 21 and the lower frame 22 of the module housing 20 of the conventional technology of FIG. 1 are connected to each other, even if swelling (volume expansion) of the battery cells 110 housed inside the module housing 20 occurs, and even if the pressure caused by the swelling is concentrated on the corners, the phenomenon of damage to the corners can be relatively reduced.

[0045] That is, unlike the module housing 20 of the conventional battery module of FIG. 1 , the battery module 100 of the present disclosure does not directly couple the ends of the first frame 121 and the second frame 122, but couples the second extension 122b of the second frame 122 with a coupling plate 123 spaced apart in a direction away from the end of the first extension 121b of the first frame 121 in the extension direction. Therefore, even if the first extension 121b is pressurized by swelling of the battery cell 110 and displaces outward (in the X-axis direction), the displacement of the end of the coupling plate 123 coupled with the second extension 122b is less than the displacement of the end of the first extension 121b in the extension direction, thereby reducing damage and separation of the coupling portion of the module housing 120 (e.g., corner D in FIG. 1 ) due to swelling of the battery cell 110. Therefore, the battery module 100 of the present disclosure can increase the mechanical rigidity of the coupling portion of the module housing 120, thereby increasing durability.

[0046] 2 and 3, the first portion of the coupling plate 123 of the battery module 100 of the present disclosure may be disposed to contact an outer surface of the first extension portion 121b of the first frame 121. For example, as shown in Fig. 3, the first portion of one of the coupling plates 123 may be coupled to a left outer surface of the first extension portion 121b located on the left side of the first frame 121, and the remaining coupling plate 123 may be coupled to a right outer surface of the first extension portion 121b located on the right side of the first frame 121. For example, the coupling plate 123 may be plate-shaped, and the first portion may be a wide surface of the plate-shaped coupling plate.

[0047] 3, the inner surface of the second extension portion 122b may face the outer surface of the first extension portion 121b of the first frame 121. For example, as shown in FIG. 3, the inner surface of the second extension portion 122b may face the left outer surface of the first extension portion 121b located on the left side of the first frame 121, and the remaining second extension portion 122b may face the right outer surface of the first extension portion 121b located on the right side of the first frame 121. The inner surface of the second extension portion 122b may be located closer to the cover portion 121a than the first portion.

[0048] An end portion S in the extension direction of each of the second extension portions 122b of the second frame 122 may be coupled to the second portion of the coupling plate 123. For example, as shown in FIGS. 2 and 4, one of the second extension portions 122b of the second frame 122 located on the relatively left side may have an end portion (lower surface) extending from the cover portion 122a coupled to the upper end (second portion) of the coupling plate 123. The remaining second extension portion 122b located on the relatively right side may have an end portion extending from the cover portion 122a coupled to the upper end (second portion) of the coupling plate 123. Here, welding may be used as the coupling method. For example, the welding may be laser welding.

[0049] Also, the first and second portions of the coupling plate 123 may be disposed on different planes.

[0050] According to this configuration of the present disclosure, the first portion of the coupling plate 123 of the battery module 100 of the present disclosure is disposed on the outer surface of the first extension portion 121b of the first frame 121, thereby preventing damage to the battery cells 110 accommodated inside the module housing 120 that may occur during the process of coupling the second extension portion 122b and the coupling plate 123. That is, in the battery module 100 of the present disclosure, the first portion of the coupling plate 123 is disposed outside the first extension portion 121b of the first frame 121, thereby preventing the battery cells 110 accommodated in the module housing 120 from being heated by welding heat generated during the process of welding the second extension portion 122b and the coupling plate 123, or preventing high-temperature welding debris from moving to the battery cells 110 and damaging the cases of the battery cells 110. As a result, the structure of the battery module 100 of the present disclosure can reduce the defect rate due to damage to the battery cells 110 that may occur during the process of coupling the second extension portion 122b and the coupling plate 123.

[0051] Fig. 5 is a perspective view schematically illustrating a battery module 100 according to another embodiment of the present disclosure, and Fig. 6 is a partial front view schematically illustrating a portion of a module housing 120 of the battery module 100 according to another embodiment of the present disclosure.

[0052] 5 and 6, a first portion of a coupling plate 123 of a battery module 100 according to another embodiment of the present disclosure may be disposed to contact an inner surface of a first extension portion 121b of a first frame 121. The first and second portions of the coupling plate 123 may be disposed on different planes. For example, as shown in FIG. 6, an outer surface of one of the coupling plates 123 may be coupled to an inner surface of the first extension portion 121b located on the left side of the first frame 121. In addition, an outer surface of the remaining coupling plate 123 located on the relatively right side may be coupled to an inner surface of the second extension portion 122b located on the right side of the first frame 121.

[0053] 6, one outer surface of the second extension portion 122b may face the inner surface of the first extension portion 121b of the first frame 121. The other second extension portion 122b may face the inner surface of the first extension portion 121b located on the left side of the first frame 121. The other second extension portion 122b located on the right side may face the inner surface of the first extension portion 121b located on the right side of the first frame 121. The outer surface of the second extension portion 122b may be located closer to the cover portion 121a than the first portion of the coupling plate 123.

[0054] Furthermore, an end portion in the extension direction of the second extension portion 122b of the second frame 122 may be coupled to the coupling plate 123. For example, as shown in Fig. 6, one of the second extension portions 122b of the second frame 122 located on the relatively left side may have an end portion extending from the cover portion 122a coupled to the upper end of the coupling plate 123. The remaining second extension portion 122b located on the relatively right side may have an end portion extending from the cover portion 122a coupled to the upper end of the coupling plate 123. Here, welding may be used as the coupling method. For example, the welding may be laser welding.

[0055] Therefore, according to this configuration of the present disclosure, the coupling plate 123 of the battery module 100 of the present disclosure is located on the inner surface of the first extension portion 121b of the first frame 121, so that there is no protruding portion on the exterior of the module housing 120. This reduces interference (disturbance) that may occur during the process of storing the battery module 100 in a storage space that stores the battery module 100 inside a vehicle, for example, and makes it easier for workers to install or replace the battery module 100. In addition, the space occupied by the battery module 100 in the storage space can be reduced, allowing the number of battery modules 100 that can be installed in a battery storage space of the same size to be increased.

[0056] 2, in the battery module 100 according to an embodiment of the present disclosure, each of the second extensions 122b of the second frame 122 may be joined to at least one side of the coupling plate 123. As shown in FIG. 2, each of the second extensions 122b may be configured to couple to an upper side of the coupling plate 123 coupled to the first extension 121b. However, this coupling structure is not necessarily limited thereto. For example, each of the second extensions 122b may be coupled to an upper side (Z-axis direction), a front side (negative Y-axis direction), and a rear side (positive Y-axis direction) of the coupling plate 123. In this case, a stronger coupling force may be achieved than when the second extensions 122b are coupled only to the upper side of the coupling plate 123, thereby improving the durability of the module housing 120.

[0057] Fig. 7 is a partial perspective view schematically illustrating a portion of second frame 122 of battery module 100 according to an embodiment of the present disclosure. Fig. 8 is a partial perspective view schematically illustrating a portion of first frame 121 and joining plate 123 of battery module 100 according to an embodiment of the present disclosure. Fig. 9 is a partial perspective view schematically illustrating a portion of first frame 121 and joining plate 123 of battery module 100 according to an embodiment of the present disclosure. For reference, Fig. 7 shows an enlarged view of region A in Fig. 3, and Fig. 9 shows an enlarged view of region B in Fig. 8.

[0058] 2 and 7 to 9, at least one coupling groove H may be formed in the second extension portion 122b of the second frame 122 of the battery module 100 according to an embodiment of the present disclosure. For example, as shown in FIG. 7, the second extension portion 122b may have a plurality of coupling grooves H spaced apart at predetermined intervals. For example, three coupling grooves H may be formed. The coupling groove H may not be welded to the coupling plate 123, or an inner surface of the coupling groove H may be welded to a portion of the coupling plate 123 to increase the coupling strength between the second extension portion 122b and the coupling plate 123. For example, as shown in FIG. 7, the coupling groove H may have a rectangular groove shape on a side surface.

[0059] The coupling plate 123 may also include a protruding insert 123a configured to be inserted into the coupling groove H. For example, as shown in FIG. 9, the coupling plate 123 includes the protruding insert 123a formed on the upper end (second portion) of the coupling plate 123. The protruding insert 123a may have a shape that protrudes from the end of the coupling plate 123. The protruding shape may have a shape that corresponds to the coupling groove H. That is, the coupling groove H and the protruding insert 123a may be engaged with each other to be coupled. For example, as shown in FIG. 9, the protruding insert 123a of the coupling plate 123 may have a square protruding shape on a side surface. If necessary, the protruding insert 123a may be welded to the coupling groove H to increase the coupling strength between the coupling plate 123 and the second extension 122b.

[0060] According to this configuration of the present disclosure, the battery module 100 according to an embodiment of the present disclosure has a coupling groove H formed in the second extension portion 122b of the second frame 122, and includes a protruding insertion portion 123a configured to couple with the coupling groove H on the coupling plate 123. The coupling structure of the coupling groove H and the protruding insertion portion 123a can limit the movement of the second extension portion 122b in the front-rear direction (Y-axis direction) when the second extension portion 122b is disposed above the coupling plate 123. This allows stable welding between the second extension portion 122b and the coupling plate 123. The battery module 100 of the present disclosure can increase the coupling strength between the second frame 122 and the coupling plate 123, thereby effectively improving the durability of the module housing 120.

[0061] FIG. 10 is a partial side view that schematically illustrates a part of a second frame 122 and a joining plate 123 of a battery module 100 according to another embodiment of the present disclosure.

[0062] Also, referring to FIG. 10 together with FIG. 2, a battery module 100 according to another embodiment of the present disclosure may have the same configuration as the battery module 100 of FIG. 2, except that a wedge-shaped protrusion P is further formed on the protruding insertion portion 123a of the coupling plate 123.

[0063] The battery module 100 according to another embodiment of the present disclosure of FIG. 10 may further include wedge-shaped protrusions P configured to press against the inner surface of the coupling groove H. The wedge-shaped protrusions P may be formed on the protruding insertion portion 123a of the coupling plate 123, and may be formed on both sides of the protruding insertion portion 123a in the front-rear direction (negative and positive directions of the Y axis) as shown in FIG. 10 . The wedge-shaped protrusions P may protrude from the end of the protruding insertion portion 123a toward the coupling groove H. For example, as shown in FIG. 10 , the wedge-shaped protrusions P of the coupling plate 123 may have a rounded shape protruding toward the inner surface of the coupling groove H. The wedge-shaped protrusions P may be formed on the front and rear ends of the protruding insertion portion 123a. The wedge-shaped protrusions P formed at the front and rear ends of the protruding insertion portion 123a may have shapes that protrude forward and backward, respectively, to press against the coupling groove H formed in the second extension portion 122b of the second frame 122. The protruding insertion portion 123a may be coupled with the coupling groove H in a state in which the wedge-shaped protrusions P press against the coupling groove H.

[0064] According to this configuration of the present disclosure, the battery module 100 of the present disclosure includes the wedge-shaped protrusion P formed on the protruding insertion portion 123a of the coupling plate 123, thereby effectively increasing the coupling force between the coupling groove H formed on the second extension portion 122b of the second frame 122 and the protruding insertion portion 123a of the coupling plate 123. As a result, the battery module 100 of the present disclosure can increase the coupling force between the second frame 122 and the coupling plate 123, and effectively increase the durability of the module housing 120.

[0065] FIG. 11 is a partial front view that schematically illustrates a part of a module housing 120 of a battery module 100 according to another embodiment of the present disclosure.

[0066] 2 and 3, in a battery module 100 according to another embodiment of the present disclosure, a first inclined surface K1 may be formed on a portion of the second extension 122b that is coupled to the second portion of the coupling plate 123. The second extension 122b of the second frame 122 may have the first inclined surface K1 formed on at least a portion of the second portion that is coupled to the coupling plate 123. For example, as shown in FIG. 11, the first inclined surface K1 may be formed on a lower end surface of the second extension 122b that is coupled to an upper end surface of the coupling plate 123.

[0067] In addition, a second inclined surface K2 parallel to the first inclined surface K1 may be formed on a second portion of the coupling plate 123 coupled to the second extension portion 122b. The second inclined surface K2 may be formed on at least a portion of an end (second portion) of the coupling plate 123 coupled to the second extension portion 122b of the second frame 122. For example, as shown in FIG. 11 , the second inclined surface K2 may be formed on at least a portion of an upper end surface of the coupling plate 123 coupled to a lower end surface of the second extension portion 122b of the second frame 122.

[0068] Therefore, according to this configuration of the present disclosure, the battery module 100 of the present disclosure forms the first inclined surface K1 and the second inclined surface K2 on at least a portion of each end where the second extension portion 122b of the second frame 122 and the coupling plate 123 are coupled to each other, thereby increasing the coupling area between the second extension portion 122b of the second frame 122 and the coupling plate 123. As a result, the battery module 100 of the present disclosure can increase the coupling force between the second frame 122 and the coupling plate 123, and can effectively increase the durability of the module housing 120.

[0069] More specifically, the height of the first inclined surface K1 may be gradually decreased toward the inside of the battery module 100. For example, as shown in FIG. 11 , the height of the first inclined surface K1 may be gradually decreased toward the first extension portion 121b of the first frame 121. Furthermore, the height of the second inclined surface K2 may be gradually increased toward the outside of the battery module 100 (the negative or positive direction of the X-axis). For example, as shown in FIG. 11 , the height of the second inclined surface K2 of the coupling plate 123 may be gradually increased in a direction opposite to the direction toward the first extension portion 121b of the first frame 121. Here, the first inclined surface K1 and the second inclined surface K2 may be parallel to each other and may be disposed in close contact with each other. Furthermore, the second extension portion 122b may be supported upward by the second inclined surface K2 of the coupling plate 123. Here, the second extension 122b may be subjected to a force that moves it downward along the second inclined surface K2 due to gravity, and a force that moves it toward the first extension 121b of the first frame 121. As a result, the second extension 122b may be disposed in close contact with the outer surface of the first extension 121b of the first frame 121.

[0070] Therefore, according to this configuration of the present disclosure, the battery module 100 of the present disclosure has the first inclined surface K1 having a shape in which the height of the inclined surface continuously decreases toward the inside of the battery module 100, and the second inclined surface K2 having a shape in which the height of the inclined surface continuously increases toward the outside of the battery module 100, so that the coupling structure of the first inclined surface K1 and the second inclined surface K2 can stably fix the second extension portion 122b of the second frame 122 in position without separating from the position facing the coupling plate 123. As a result, the battery module 100 of the present disclosure has the second extension portion 122b of the second frame 122 stably fixed to one side of the coupling plate 123, which can improve the efficiency of a coupling process, such as welding, between the second extension portion 122b of the second frame 122 and the coupling plate 123.

[0071] FIG. 12 is a partial front view schematically illustrating a part of a module housing 120 of a battery module according to still another embodiment of the present disclosure.

[0072] 12 together with FIG. 2, a battery module according to yet another embodiment of the present disclosure may further include a stopper 123b on the coupling plate 123, compared to the battery module 100 of FIG. 2. The remaining configuration of the battery module 100 of FIG. 12 may be the same as that of the battery module 100 of FIG. 2.

[0073] The coupling plate 123 of a battery module 100 according to another embodiment of the present disclosure may include a stopper 123b configured to prevent the second extension portion 122b of the second frame 122 from separating from the coupling position with the coupling plate 123. The stopper 123b may be formed by extending from the second portion (upper end) to surround the outside of the second extension portion 122b. The stopper 123b may also be positioned to face the outer surface (negative or positive direction of the X-axis) of the second extension portion 122b of the second frame 122. For example, as shown in FIG. 12 , the coupling plate 123 of the battery module 100 according to the present disclosure may include a stopper 123b bent outward (negative direction of the X-axis) from the upper end of the coupling plate 123 and bent upward (in the Z-axis direction). The stopper 123b may be configured to support an end of the second extension portion 122b of the second frame 122 toward the first extension portion 121b of the first frame 121. That is, the second extension portion 122b may be interposed between the stopper 123b and the first extension portion 121b. Although not shown, the coupling plate 123 located on the right side of the battery module 100 may also be provided with a stopper 123b having the same function. That is, the coupling plate 123 located on the right side may be provided with a stopper 123b that stably fixes the second extension portion 122b of the second frame 122 located on the right side of the battery module 100. For example, as shown in FIG. 12, the stopper 123b may be bent outward (in the negative direction of the X-axis) from the upper end of the coupling plate 123 and also bent upward (in the Z-axis direction). Although not shown separately, the stopper 123b provided on the coupling plate 123 located on the right side of the battery module 100 may be bent outward (positive direction of the X-axis) from the upper end of the coupling plate 123 and also bent upward (in the Z-axis direction).

[0074] Therefore, according to such a configuration of the present disclosure, the joining plate 123 of the battery module 100 according to another embodiment of the present disclosure is provided with a stopper 123b that protrudes from one end so as to surround and face the outer surface of the second extension portion 122b of the second frame 122, thereby enabling the second extension portion 122b of the second frame 122 to be stably fixed to one side of the joining plate 123, and enabling the joining process of the second extension portion 122b and the joining plate 123 to be performed quickly without using a separate fixing jig, and also increasing the reliability of the joining (welding).

[0075] FIG. 13 is a perspective view that schematically illustrates a battery pack 200 according to an embodiment of the present disclosure.

[0076] 13 together with FIG. 2, the present disclosure provides a battery pack 200 including at least one battery module 100 according to an embodiment. Specifically, the battery pack 200 of the present disclosure may include a battery management system (BMS) 230 configured to control charging and discharging of the battery module 100. The battery pack 200 may also include an external output terminal 220 provided at its front end. The bus bars, pack housing, and the like of the battery pack 200 may be configured as known components, and therefore, description of these components will be omitted.

[0077] FIG. 14 is a schematic diagram illustrating an automobile 300 according to an embodiment of the present disclosure.

[0078] 14 in addition to FIG. 2, the present application provides an automobile 300 including at least one battery module 100 according to an embodiment of the present disclosure. The automobile 300 of the present disclosure may include a vehicle body (chassis) configured to mount the battery module 100 thereon. The automobile 300 may be, for example, a hybrid vehicle or an electric vehicle.

[0079] 2 and 3, the present application provides a method for manufacturing a battery module 100 according to an embodiment of the present disclosure. Also referring to FIGS. 2 to 4, the method for manufacturing the battery module 100 includes the steps of: preparing at least one battery cell 110; preparing a first frame 121 having an accommodating space for accommodating the at least one battery cell 110 and including a main body 121a and first extensions 121b extending in at least one direction from both ends of the main body 121a; mounting the at least one battery cell 110 in the accommodating space of the first frame 121; and mounting a storage portion 121b facing the main body 121a. The method includes the steps of preparing a second frame 122 having a cover portion 122a that covers a storage space and second extension portions 122b that extend in at least one direction from both ends of the cover portion 122a and are configured to face the first extension portions 121b, respectively, attaching a plurality of attachment plates 123 to the outer surface of the first extension portion 121b so that the attachment plates 123 are spaced apart in a direction away from the end of the first extension portion 121b of the first frame 121 in the extension direction, and attaching the second portion to the second extension portion 122b. The attachment plate 123 may include a first portion that is a plate-shaped wide surface that attaches to the outside of the first extension portion 121b and a second portion that attaches to the end of the second extension portion 122b. The attachment of the first and second portions may be performed by welding.

[0080] Therefore, according to this configuration of the present disclosure, the manufacturing method of the battery module 100 of the present disclosure does not require the second extension portion 122b of the second frame 122 to be connected to the first extension portion 121b of the first frame 121 but to a plurality of separate connecting plates 123, thereby eliminating the need to increase the thickness of the first frame 121 or the second frame 122 to increase the connecting area of ​​the first frame 121 or the second frame 122, as compared to the module housing 20 of the prior art shown in FIG. 1, which has a structure in which the upper cover 21 and the lower frame 22 are directly connected. As a result, the battery module 100 of the present disclosure can reduce the material cost of the module housing 120 and achieve a reduction in the weight of the battery module 100.

[0081] Furthermore, the manufacturing method of the battery module 100 disclosed herein includes a connecting plate 123 spaced apart in a direction away from the end of the extension direction of the first extension portion 121b of the first frame 121, so that the connecting portion between the connecting plate 123 and the second extension portion 122b of the second frame 122 has excellent resistance to pressure caused by the swelling (volume expansion) phenomenon of the battery cells housed inside the module housing 20, and can relatively reduce the phenomenon of damage or separation between the connecting plate 123 and the second extension portion 122b of the second frame 122 compared to the connecting portion formed at the corner of the module housing 20 of the conventional technology of Figure 1.

[0082] Furthermore, by providing the battery module 100 of the present disclosure with a separate connecting plate 123, there is no need to increase the thickness of the first frame 121 or the second frame 122 of the module housing 120 to increase the connecting area of ​​the first frame 121 or the second frame 122, compared to a structure in which the upper cover 21 and the lower frame 22 are directly connected, such as the module housing 20 of the conventional battery module of Figure 1, thereby reducing manufacturing costs and enabling the battery module 100 to be made lighter.

[0083] Furthermore, in the battery module 100 of the present disclosure, the coupling plate 123 may be welded to the outer surface of the first extension portion 121b and the end portion of the second extension portion 122b in the extension direction. That is, the first portion of the coupling plate 123 and the outer side of the first extension portion 121b may be welded to each other. Also, the second portion of the coupling plate 123 and the end portion of the second extension portion 122b may be welded to each other. For example, the inner surface (right or left side) of the coupling plate 123 may be welded to the outer surface (left or right side) of the first extension portion 121b. The upper surface of the coupling plate 123 may be welded to the lower surface of the first extension portion 121b.

[0084] Furthermore, at least two of the coupling plate 123, the first extension 121b, and the second extension 122b may be made of the same material. For example, the coupling plate 123, the second extension 122b, and the second extension 122b may all be made of one or more of steel, aluminum alloy, and stainless steel. For example, the second extension 122b and the coupling plate 123 may all be made of aluminum alloy, and the first extension 121b may be made of stainless steel.

[0085] Therefore, according to this configuration of the present disclosure, the manufacturing method of the battery module 100 of the present disclosure can enable welding of the same metal between the components by using the same material for at least two of the joining plate 123, the first extension 121b, and the second extension 122b. In particular, even if the first extension 121b and the second extension 122b are made of dissimilar metals, by using the same metal as the second extension 122b for the joining plate 123, the welding process can be performed using welding of the same metal even if the joining area between the joining plate 123 and the second extension 122b is small, thereby ensuring high joining strength.

[0086] Although the embodiments have been described above with limited drawings, those skilled in the art can apply various technical modifications and variations based on the above. For example, the above techniques may be performed in a different order than the above-described method, and / or the components of the above-described systems, structures, devices, circuits, etc. may be combined or combined in a different manner than the above-described method, or may be replaced or replaced by other components or equivalents, and still achieve suitable results.

[0087] Accordingly, other implementations, other embodiments, and equivalents of the claims are within the scope of the following claims. [Explanation of symbols]

[0088] 20 Module Case 21, 22 Upper cover, lower frame 100 Battery Module 110 battery cells 120 module housing 121, 122 1st frame, 2nd frame 121a, 122a Main body, cover 121b, 122b 1st extension, 2nd extension 123 Binding Plate H binding groove 123a Protruding insert P wedge-shaped protrusion K1, K2 1st slope, 2nd slope 123b Stopper 200 Battery Pack 300 cars

Claims

1. at least one battery cell; A module housing; A battery module comprising: The module housing includes: a first frame including a main body and first extensions extending in at least one direction from both ends of the main body so as to form an accommodation space for accommodating at least one of the battery cells; a second frame including a cover portion facing the main body portion to cover the storage space, and second extension portions extending in at least one direction from both ends of the cover portion and positioned to face the first extension portions, respectively; a coupling plate spaced from an end portion of the first extension of the first frame in the extension direction, the coupling plate including a first portion coupled to an inner surface or an outer surface of the first extension and a second portion coupled to the end portion of the second extension in the extension direction; A battery module comprising:

2. the first portion and the second portion are disposed on different planes; the first portion of the coupling plate is disposed in contact with an outer surface of the first extension portion; The battery module according to claim 1 , wherein an inner surface of the second extension portion faces an outer surface of the first extension portion and is disposed at a position closer to the cover portion than the first portion.

3. the first portion and the second portion are disposed on different planes; the first portion of the coupling plate is disposed so as to contact an inner surface of the first extension portion of the first frame; The battery module according to claim 1 , wherein an outer surface of the second extension portion faces an inner surface of the first extension portion and is disposed at a position closer to the cover portion than the first portion.

4. The battery module according to claim 1 , wherein the first portion is a plate-shaped wide surface of the joining plate and is in contact with the first extension, and the second portion is opposite and in contact with an end of the second extension.

5. The second extension portion of the second frame has A coupling groove having a recessed shape in the opposite direction to the extension direction is formed from the end of the extension direction, The coupling plate is The battery module according to claim 1 , wherein the second portion includes a protruding insert portion protruding from an end of the coupling plate to be inserted into the coupling groove.

6. The battery module according to claim 5 , wherein the protruding insertion portion includes a wedge-shaped protrusion protruding from an end of the protruding insertion portion to press an inner surface of the coupling groove.

7. a first inclined surface is formed on a portion of the second extension portion that is coupled to the second portion of the coupling plate; The battery module according to claim 1 , wherein the second portion of the coupling plate coupled to the second extension portion has a second inclined surface formed thereon that is parallel to the first inclined surface.

8. The first inclined surface has a shape in which a height of the first inclined surface continuously decreases toward an inner side of the battery module, The battery module according to claim 7 , wherein the second inclined surface has a shape in which the height of the second inclined surface increases continuously in an outward direction of the battery module.

9. the first portion is a plate-shaped wide surface of the coupling plate, and the second portion faces and contacts an end of the second extension portion; The coupling plate is The battery module according to claim 1 , further comprising a stopper extending from the second portion so as to surround the second extension.

10. The coupling plate is The battery module according to claim 1 , wherein the battery module is formed to have an elongated shape in a direction parallel to the first extension portion and the second extension portion.

11. A battery pack comprising at least one battery module according to any one of claims 1 to 10.

12. A motor vehicle comprising at least one battery module according to any one of claims 1 to 10.

13. A method for manufacturing the battery module according to claim 1, providing at least one battery cell; preparing a first frame having an accommodation space for accommodating at least one of the battery cells, the first frame including a main body and first extensions extending in at least one direction from both ends of the main body; Mounting at least one battery cell in the receiving space of the first frame; preparing a second frame including a cover portion that faces the main body portion and covers the storage space, and second extension portions that extend in at least one direction from both ends of the cover portion and are configured to face each of the first extension portions; a step of coupling a plurality of coupling plates to an outer surface of the first extension of the first frame so as to be spaced apart from an end portion of the first extension in an extension direction of the first extension, the coupling plates including a first portion having a wide plate-like surface coupled to an outer side of the first extension and a second portion coupled to an end portion of the second extension, the coupling plates being coupled to the outer surface of the first extension; coupling the second portion of the coupling plate to the second extension; A method for manufacturing a battery module, comprising:

14. The first portion and the outer side of the first extension portion are joined by welding; The second portion and the end portion of the second extension are joined by welding; The method for manufacturing a battery module according to claim 13 , wherein at least two of the joining plate, the first extension, and the second extension are made of the same material.

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