Battery module and method of manufacturing the same

Abstract

A battery module according to one embodiment of the present invention comprises: a battery cell stack having a plurality of battery cells stacked thereon; a module frame accommodating the battery cell stack; and an insulating member positioned between the battery cell stack and the module frame, wherein the insulating member continuously covers the lower and both sides of the battery cell stack.

Description

Technology Field

[0001] The present invention relates to a battery module and a method for manufacturing the same, and more specifically, to a battery module with improved assembly and insulation properties and a method for manufacturing the same. Background Technology

[0002] With the increasing technological development and demand for mobile devices, the demand for secondary batteries as an energy source is rapidly increasing. In particular, secondary batteries are attracting significant interest as an energy source not only for mobile devices such as mobile phones, digital cameras, laptops, and wearable devices, but also for power devices such as electric bicycles, electric vehicles, and hybrid electric vehicles.

[0003] Recently, with the increasing need for high-capacity secondary battery structures, including their utilization as energy storage sources, there is a growing demand for battery modules in which multiple secondary batteries are connected in series or parallel, and for battery packs with a multi-module structure that aggregates said battery modules.

[0004] Meanwhile, when configuring a battery pack by connecting multiple battery cells in series or parallel, it is common practice to configure a battery module consisting of at least one battery cell and to configure the battery pack by adding other components using this at least one battery module.

[0005] FIG. 1 is an exploded perspective view of a conventional battery module. FIG. 2 is a drawing showing the assembled battery module of FIG. 1. FIG. 3 is a drawing showing a pressure jig during the assembly of a conventional battery module.

[0006] Referring to FIGS. 1 and 2, a conventional battery module (10) includes a battery cell stack (12) in which a plurality of battery cells (11) are stacked, and a module frame (20) that accommodates the battery cell stack (12). At this time, the module frame (20) may include a U-shaped module frame (30) that covers the side and bottom of the battery cell stack (12), and an upper plate (40) that covers the upper side of the battery cell stack. Additionally, the battery module (10) includes an end plate (15) that covers the front and back of the battery cell stack (12), and a bus bar frame (13) may be formed between the battery cell stack (12) and the end plate (15). At this time, the battery cell stack (12) and the bus bar frame (13) may be assembled to form a cell assembly.

[0007] At this time, referring to FIG. 3, for the assembly of a conventional battery module (10), a plurality of battery cells (11) are first stacked to form a battery cell stack (12). Next, the battery cell stack (12) is pressed with a pressure jig (60) and electrode leads are welded to form a cell assembly, and the cell assembly is housed inside a module frame (20).

[0008] However, when the battery cell stack (12) itself is pressed with a pressure jig (60) and the electrode leads are welded, and the cell assembly formed through the above process is housed in a module frame, there is a high possibility of deformation of the battery cell (11) and the battery cell stack (12).

[0009] In addition, there was a problem in that the position of the electrode lead part was not fixed because the position of the electrode lead part was changed before and after the pressurization due to the pressurization.

[0010] Therefore, there is a need for a structure that minimizes the possibility of deformation of the battery cell (11) and the battery cell stack (12), and ensures that the position of the electrode lead part is maintained even when pressed by the pressure jig (60), thereby improving the assembly and structural stability of the battery module and securing insulation. The problem to be solved

[0011] The problem to be solved by the present invention is to provide a battery module with improved assembly and insulation properties and a method for manufacturing the same.

[0012] The problems that the present invention aims to solve are not limited to those described above, and problems not mentioned will be clearly understood by those skilled in the art from this specification and the attached drawings. means of solving the problem

[0013] A battery module according to one embodiment of the present invention comprises: a battery cell stack having a plurality of battery cells stacked thereon; a module frame accommodating the battery cell stack; and an insulating member positioned between the battery cell stack and the module frame, wherein the insulating member continuously covers the lower and both sides of the battery cell stack.

[0014] The above insulating member can come into contact with the bottom portion of the module frame.

[0015] The above-mentioned module frame may further include a thermally conductive resin layer located at the bottom portion, wherein the thermally conductive resin layer may include a first thermally conductive resin layer and a second thermally conductive resin layer spaced apart from each other based on the insulating member portion in contact with the bottom portion of the module frame.

[0016] The insulating member may further include an extension extending from both sides of the battery cell stack and covering at least a portion of the upper part of the battery cell stack.

[0017] The module frame includes a frame member covering the lower and both sides of the battery cell stack and an upper plate covering the upper part of the battery cell stack, the extension is located between the upper part of the battery cell stack and the upper plate, and the insulating member may include a fold formed at the portion where the extension starts.

[0018] The insulating member includes a bottom portion covering the lower part of the battery cell stack and side portions covering both sides of the battery cell stack, and the bottom portion and the side portions may be formed integrally.

[0019] The above extension may be formed integrally with the bottom portion and the side portion.

[0020] In another embodiment of the present invention, a battery module may have a groove formed in the extension portion.

[0021] A method for manufacturing a battery module according to another embodiment of the present invention comprises the steps of: stacking battery cells to form a battery cell stack; wrapping the lower and both sides of the battery cell stack with an insulating member; welding electrode leads to the battery cells to form a cell assembly while the battery cell stack is wrapped with the insulating member; and housing the cell assembly in a module frame.

[0022] The insulating member may further include an extension formed by extending from both sides of the cell assembly.

[0023] A handle for transporting the cell assembly may be formed on the extension part, or a connection part connected to a transport device may be formed.

[0024] After accommodating the cell assembly in the module frame, the method may further include the step of bending the extension portion so as to be adjacent to the upper portion of the cell assembly.

[0025] A battery pack according to another embodiment of the present invention may include the battery module. Effects of the invention

[0026] A battery module according to one embodiment of the present invention includes an insulating member that is pressed by a pressure jig, thereby applying minimal pressure to the battery cell stack and cell assembly, which minimizes positional deformation of the electrode lead portion and can improve the assemblability and structural stability of the battery module.

[0027] In addition, the insulation performance of the battery module can be improved by forming an insulating member between the battery cell stack and the module frame.

[0028] In addition, the battery cell stack and cell assembly can be easily lifted by means of an insulating member, thereby increasing assembly convenience.

[0029] However, the effects of the present invention are not limited to the effects described above, and unmentioned effects will be clearly understood by those skilled in the art from this specification and the accompanying drawings. Brief explanation of the drawing

[0030] Figure 1 is an exploded view of a conventional battery module. Figure 2 is a drawing showing the assembled battery module of Figure 1. Figure 3 is a drawing showing a part of the configuration of a conventional battery module and a pressure jig. FIG. 4 is an exploded perspective view of a battery module according to one embodiment of the present invention. FIG. 5 is a drawing showing a cell assembly and an insulating member of a battery module according to one embodiment of the present invention. FIG. 6 is a drawing showing a cell assembly and an insulating member housed in a module frame of a battery module according to one embodiment of the present invention. FIG. 7 is a drawing showing a cell assembly and an insulating member housed in a module frame of a battery module according to another embodiment of the present invention. FIG. 8 is a drawing showing a part of the battery module of the present invention and a pressure jig. FIG. 9 is a drawing showing a method for manufacturing a battery module according to another embodiment of the present invention. Specific details for implementing the invention

[0031] Hereinafter, embodiments of the present invention are described in detail so that those skilled in the art can easily implement the invention. However, the present invention may be embodied in various different forms and is not limited to the embodiments described herein.

[0032] To clearly explain the present invention, parts unrelated to the explanation have been omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0033] Furthermore, the size and thickness of each component shown in the drawings are depicted arbitrarily for convenience of explanation, and thus the present invention is not necessarily limited to what is illustrated. Thicknesses have been enlarged in the drawings to clearly represent various layers and regions. Additionally, for convenience of explanation, the thickness of some layers and regions has been exaggerated in the drawings.

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

[0035] Furthermore, throughout the specification, when a part is described as "including" a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0036] Additionally, throughout the specification, "planar" means when the subject part is viewed from above, and "cross-sectional" means when the cross-section obtained by vertically cutting the subject part is viewed from the side.

[0037] The first and second terms used in this application may be used to describe various components, but the components should not be limited by the terms. The terms are used solely for the purpose of distinguishing one component from another.

[0039] Hereinafter, a battery module including an insulating member according to an embodiment of the present invention will be described with reference to FIGS. 4 to 6 and FIG. 8.

[0040] FIG. 4 is an exploded perspective view of a battery module according to an embodiment of the present invention. FIG. 5 is a drawing showing a cell assembly and an insulating member of a battery module according to an embodiment of the present invention. FIG. 6 is a drawing showing a cell assembly and an insulating member housed in a module frame of a battery module of the present invention. FIG. 8 is a drawing showing a pressure jig for applying pressure to a battery module of the present invention.

[0041] Referring to FIG. 4, a battery module (100) according to the present embodiment includes a battery cell stack (120) in which a plurality of battery cells (110) are stacked, a module frame (200) that accommodates the battery cell stack (120), and an end plate (150) that covers the front and rear surfaces of the battery cell stack (120). At this time, the battery module (100) further includes a bus bar frame (130) located between the end plate (150) and the battery cell stack (120). At this time, the battery cell stack (120) and the bus bar frame (130) can be combined to form a cell assembly (140).

[0042] The battery cell (110) is a secondary battery and may be composed of a pouch-type secondary battery. The battery cell (110) may be composed of a plurality of such battery cells, and the plurality of battery cells (110) may be stacked together so as to be electrically connected to each other to form a battery cell stack (120), and may form a cell assembly (140) including the battery cell stack (120). Each of these plurality of battery cells (110) may include an electrode assembly, a battery case, and an electrode lead (111) protruding from the electrode assembly.

[0043] The module frame (200) includes a frame member (300) that covers the lower and side portions of the battery cell stack (120) with the upper surface, front and rear surfaces open, and an upper plate (400) that covers the upper portion of the battery cell stack (120). However, the module frame (200) is not limited thereto and may be replaced with a frame of other shapes, such as an L-shaped frame or a mono frame that surrounds the battery cell stack (120) excluding the front and rear surfaces. The battery cell stack (120) housed inside the module frame (200) can be physically protected through the module frame (200). At this time, the frame member (300) may include a frame bottom portion (300a) that supports the lower portion of the battery cell stack (120) and frame side portions (300b) that extend upward from each end of the frame bottom portion (300a).

[0044] The upper plate (400) can cover the open upper side of the module frame (200). The end plate (150) can cover the front and rear sides of the battery cell stack (120). The end plate (150) can be joined to the front and rear corners of the upper plate (400) and the front and rear corners of the module frame (200) through welding.

[0045] A bus bar frame (130) may be formed between the end plate (150) and the front and rear surfaces of the battery cell stack (120). A plurality of bus bars mounted on the bus bar frame (130) may be formed to protrude from the battery cells (110) and may come into contact with electrode leads (111) mounted on the bus bar frame (130).

[0046] Additionally, the battery module (100) of the present invention may further include a thermally conductive resin layer (700) located at the bottom portion of the module frame (200), that is, at the bottom portion of the frame (300a). As described below, the thermally conductive resin layer (700) may include a first thermally conductive resin layer (700a) and a second thermally conductive resin layer (700b) spaced apart based on the portion of the insulating member (500) that contacts the bottom portion of the module frame (200), which is the bottom portion of the frame (300a). Accordingly, the insulating member (500) is formed between the thermally conductive resin layers (700) and can perform the role of an insulating pad.

[0047] In addition, according to an embodiment of the present invention, a cell assembly (140) inserted into a module frame (200) can be covered with an upper plate (400) to form a battery module as illustrated in FIG. 2.

[0049] Conventionally, after forming a battery cell stack, electrode leads were welded while the battery cell stack was pressed with a pressure jig, and the cell assembly formed by the welded electrode leads was housed in a module frame. However, as the battery cell stack itself was pressed with the pressure jig, deformation of the battery cells and the battery cell stack occurred, and the position of the electrode leads was not fixed. This problem arose because the battery cells were compressed toward the center of the battery cell stack as the pressure jig pressed the stack, thus necessitating a structure capable of minimizing the pressure applied to the battery cell stack.

[0050] According to the present embodiment, the battery module of the present invention includes an insulating member (500) positioned between the battery cell stack (120) and the module frame (200) as shown in FIG. 4, in order to minimize the possibility of deformation of the battery cell stack (120) by the pressure jig (600) and to fix the position of the electrode lead portion. The insulating member (500) may continuously cover the lower and both sides of the battery cell stack (120).

[0051] Accordingly, the pressure jig (600) presses the insulating member (500) rather than the battery cell stack (120) and performs the welding and insertion process of the electrode lead (111), thereby minimizing the pressure applied to the battery cell stack (120). As a result, the possibility of deformation of the battery cell stack (120) is minimized, and deformation of the position of the electrode lead portion can be prevented. In addition, by forming an insulating member (500) having insulating performance, the effect of improving the insulation of the battery cell stack (120) can be achieved.

[0053] Hereinafter, an insulating member formed in a battery module according to one embodiment of the present invention will be described in more detail.

[0054] Referring to FIGS. 5 and 6, the insulating member (500) can come into contact with the bottom portion of the module frame (200), and more specifically, with the frame bottom portion (300a). Since the insulating member (500) continuously covers the bottom and both sides of the battery cell stack (120), it can come into contact with the frame bottom portion (300a), which is the bottom portion of the module frame (200), and the frame side portion (300b), which is the side portion of the module frame (200).

[0055] The insulating member (500) may be formed to wrap around part or all of the lower and side portions of the battery cell stack (120). Accordingly, the insulating member (500) may come into contact with part or all of the frame bottom portion (300a), which is the bottom portion of the module frame (200), and the frame side portion (300b), which is the side portion of the module frame (200).

[0056] At this time, the insulating member (500) may further include an extension portion (500c) that extends from both sides of the battery cell stack (120) and covers at least a portion of the upper part of the battery cell stack (120). Additionally, the insulating member (500) may include a bottom portion (500a) that surrounds the lower part of the battery cell stack (120), and side portions (500b) that surround both sides of the battery cell stack (120). In particular, the bottom portion (500a) and the side portions (500b) may be formed integrally, and the extension portion (500c) may also be formed integrally with the bottom portion (500a) and the side portions (500b).

[0057] The bottom portion (500a) of the insulating member (500) can serve as an insulating layer between the battery cell stack (120) or cell assembly (140) and the module frame (200), and in particular, can serve as an insulating layer between the battery cell stack (120) and cell assembly (140) and the bottom portion (300a) of the module frame (200).

[0058] Referring to FIG. 8, the side portion (500b) of the insulating member (500) can serve as a pressurized portion by the pressurizing jig (600). Thus, the pressurizing jig (600) does not press the battery cell stack (120) and the cell assembly (140) itself, and the pressurizing by the pressurizing jig is minimized, thereby preventing deformation of the battery cell (110) and the battery cell stack (120), and allowing the position of the electrode lead portion to be fixed without deformation. In addition, the side portion (500b) of the insulating member (500) serves as an insulator between the battery cell stack (120) and the frame side portion (300b) of the module frame (200), thereby achieving an effect of improving and enhancing the insulation performance of the battery module.

[0059] The extension (500c) of the insulating member (500) can serve as a lifting member capable of easily lifting the battery cell stack (120) and the cell assembly (140). Additionally, the extension (500c) is located between the upper part of the battery cell stack (120) and the upper plate (400), and the insulating member (500) may include a fold (500d) formed at the beginning of the extension (500c). At this time, the extension (500c) can be folded by the fold (500d) to contact the battery cell stack (120) and the upper plate (400) and accommodated in the module frame (200). Thus, the extension (500c) can serve as an insulator between the upper plate (400) of the module frame (200) and the cell assembly (140).

[0060] As described above, the insulating member (500) includes a bottom portion (500a), a side portion (500b), and an extension portion (500c), thereby securing the insulation performance of the battery module and achieving an improved assembly effect. In addition, the insulating member (500) can perform a supporting role when the cell assembly (140) moves.

[0062] Hereinafter, a battery module including an insulating member according to another embodiment of the present invention will be described. Since there is overlap with the description of the insulating member described above, only the details different from the description of the insulating member described above will be explained.

[0063] FIG. 7 is a drawing showing a cell assembly and an insulating member housed in a module frame of a battery module including an insulating member according to another embodiment of the present invention.

[0064] Referring to FIG. 7, a groove (550) may be formed in the extension (500c) of the insulating member (500). The groove (550) may be formed to allow the cell assembly (140) to be lifted more easily. More specifically, the groove (550) may function as a handle for lifting the cell assembly (140), or may be formed to be connected to an assembly device for the battery module, and may be used for various purposes within the range that can improve the assembly of the battery module.

[0066] Hereinafter, with reference to FIG. 9, a method for manufacturing a battery module according to another embodiment of the present invention will be described. Since there is overlap with the description of the battery module and the insulating member included in the battery module described above, the above description will be omitted to avoid duplication.

[0067] FIG. 9 is a drawing illustrating a method for manufacturing a battery module according to another embodiment of the present invention.

[0068] Referring to FIG. 9, battery cells (110) can be stacked to form a battery cell stack (120), and an insulating member (500) can be formed to surround the bottom and both sides of the battery cell stack (120). That is, the bottom and both sides of the battery cell stack (120) can be surrounded by the insulating member (500). At this time, the insulating member (500) can surround part or all of the bottom and both sides of the battery cell stack (120).

[0069] After forming an insulating member (500) that surrounds the battery cell stack (120) as described above, the cell assembly (140) can be formed by welding an electrode lead (111) to the battery cell (110) while the battery cell stack (120) is surrounded by the insulating member (500). Accordingly, the possibility of positional deformation of the electrode lead (111) and the electrode lead portion is minimized, and deformation of the battery cell stack (120) can also be minimized.

[0070] Additionally, after forming the cell assembly (140), the cell assembly (140) can be accommodated in the module frame (200). At this time, the step of accommodating the cell assembly (140) in the module frame (200) may include accommodating the cell assembly (140) in the module frame (200) by pressing the insulating member (500) surrounding the cell assembly (140) with a pressure jig (600).

[0071] At this time, the insulating member (500) may further include an extension portion (500c) formed by extending from both sides of the battery cell stack (120). A handle for transporting the cell assembly (140) may be formed on the extension portion (500c), or a connection portion connected to a transport device may be formed, and the groove portion (550) described above may perform the role of the handle and the connection portion.

[0072] Additionally, after the cell assembly (140) is housed within the module frame (200), the extension (500c) of the insulating member (500) can be bent to come into contact with the upper portion of the cell assembly (140), and the extension (500c) can be housed within the module frame (200). Accordingly, the manufacturing method according to the present embodiment may include, after the cell assembly (140) is housed within the module frame (200), bending the extension (500c) so as to be adjacent to the upper portion of the cell assembly (140) and housed the extension (500c) within the module frame (200).

[0073] Subsequently, the method may include the step of additionally assembling an end plate (150) covering the front and rear surfaces of the cell assembly (140) and an upper plate (400) covering the top of the cell assembly (140). At this time, the assembly may be performed by welding, but is not limited thereto.

[0074] When manufacturing a battery module using the manufacturing method described above, the pressure jig (600) does not apply pressure to the battery cell stack (120) and the cell assembly (140) itself, and the pressure applied by the pressure jig is minimized, thereby preventing deformation of the battery cell (110) and the battery cell stack (120), and achieving the effect of fixing the position of the electrode lead portion without deformation.

[0076] The battery module described above may be included in a battery pack. The battery pack may have a structure in which one or more battery modules according to the present embodiment are assembled and packed with a Battery Management System (BMS) that manages the temperature or voltage of the battery, and a cooling device, etc.

[0077] The above-described battery pack can be applied to various devices. Such devices may be applied to means of transportation such as electric bicycles, electric vehicles, and hybrid vehicles, but the present invention is not limited thereto and can be applied to various devices capable of using battery modules, and this also falls within the scope of the present invention.

[0078] Although preferred embodiments of the present invention have been illustrated and described above, the present invention is not limited to the specific embodiments described above. It is understood that various modifications can be made by those skilled in the art without departing from the essence of the invention as claimed in the claims, and such modifications should not be understood individually from the technical spirit or perspective of the present invention. Explanation of the symbols

[0080] 110: Battery cell 120: Battery cell stack 130: Bus bar frame 140: Cell Assembly 150: End plate 200: Module Frame 300: Frame missing 300a: Bottom of the frame 300b: Frame side 400: Upper plate 500: Insulating member 500a, 500b, 500c, 500d: Bottom part, side part, extension part, fold part 550: Homeboo 600: Pressure jig 700: Thermally conductive resin layer

Claims

Claim 1 A battery module comprising: a battery cell stack having a plurality of stacked battery cells; a module frame accommodating the battery cell stack; and an insulating member positioned between the battery cell stack and the module frame, wherein the insulating member continuously covers the lower and both sides of the battery cell stack, and the insulating member further comprises an extension extending from both sides of the battery cell stack to cover at least a portion of the upper part of the battery cell stack. Claim 2 In claim 1, the insulating member is a battery module in contact with the bottom portion of the module frame. Claim 3 A battery module according to claim 2, further comprising a thermally conductive resin layer located at the bottom portion of the module frame, wherein the thermally conductive resin layer comprises a first thermally conductive resin layer and a second thermally conductive resin layer spaced apart from the insulating member portion in contact with the bottom portion of the module frame. Claim 4 delete Claim 5 A battery module according to claim 1, wherein the module frame comprises a frame member covering the lower and both sides of the battery cell stack and an upper plate covering the upper part of the battery cell stack, the extension portion is located between the upper part of the battery cell stack and the upper plate, and the insulating member includes a fold portion formed at the portion where the extension portion begins. Claim 6 A battery module according to claim 1, wherein the insulating member comprises a bottom portion covering the lower part of the battery cell stack and side portions covering both sides of the battery cell stack, and the bottom portion and the side portions are integrally formed. Claim 7 In claim 6, the extension portion is a battery module formed integrally with the bottom portion and the side portion. Claim 8 A battery module having a groove formed in the extension portion in claim 1. Claim 9 A method for manufacturing a battery module comprising: a step of stacking battery cells to form a battery cell stack; a step of wrapping the lower and both sides of the battery cell stack with an insulating member; a step of welding electrode leads to the battery cells to form a cell assembly while the battery cell stack is wrapped with the insulating member; and a step of housing the cell assembly in a module frame, wherein the insulating member further comprises an extension formed by extending from both sides of the cell assembly. Claim 10 delete Claim 11 A method for manufacturing a battery module according to claim 9, wherein the extension portion has a handle formed thereon for transporting the cell assembly or a connecting portion formed thereon for connecting to a transport device. Claim 12 A method for manufacturing a battery module according to claim 11, further comprising the step of folding the extension portion adjacent to the upper portion of the cell assembly after accommodating the cell assembly in the module frame. Claim 13 A battery pack comprising the battery module of claim 1.

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