Battery module and battery pack comprising same

Abstract

The technical idea of the present invention provides a battery module comprising: a plurality of battery cell assemblies, each including a plurality of battery cells; a lower case including a plurality of first pocket parts, which are spaced apart from each other in a first direction, and a first connection part, which extends between two adjacent first pocket parts from among the plurality of first pocket parts, each of the plurality of first pocket parts having a lower accommodation space for accommodating the lower part of the corresponding battery cell assembly from among the plurality of battery cell assemblies; and an upper case including a plurality of second pocket parts, which are spaced apart from each other in the first direction, and a second connection part between two adjacent second pocket parts from among the plurality of second pocket parts, each of the plurality of second pocket parts having an upper accommodation space for accommodating the upper part of the corresponding battery cell assembly from among the plurality of battery cell assemblies.

Description

Battery module and battery pack including same

[0001] The present invention relates to a battery module and a battery pack including the same.

[0002] This application claims the benefit of priority from Republic of Korea Patent Application No. 10-2023-0101567, filed August 3, 2023, the entire contents of which are incorporated herein by reference.

[0003] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. They are widely used as a power source for various wireless devices, including handsets, laptops, and cordless vacuum cleaners. Recently, improved energy density and economies of scale have dramatically reduced the per-unit manufacturing cost of secondary batteries. Furthermore, as the range of battery electric vehicles (BEVs) has increased to match that of fuel-powered vehicles, the primary use of secondary batteries is shifting from mobile devices to mobility.

[0004] As secondary batteries become increasingly used in mobility, demand for their safety is increasing. Fires and other accidents involving secondary batteries used in mobility vehicles can endanger the lives of drivers, making research into technologies that enhance secondary battery safety essential.

[0005] The technical idea of ​​the present invention is to provide a battery module and a battery pack including the same.

[0006] In order to solve the above-described problem, the technical idea of ​​the present invention provides a battery module including: a plurality of battery cell assemblies, each including a plurality of battery cells; a lower case, including a plurality of first pocket portions spaced apart from each other in a first direction and a first connecting portion extending between two adjacent first pocket portions among the plurality of first pocket portions, each of the plurality of first pocket portions having a lower receiving space for receiving a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, wherein the plurality of first pocket portions and the first connecting portion are integrally formed; and an upper case, including a plurality of second pocket portions spaced apart from each other in the first direction and a second connecting portion between two adjacent second pocket portions among the plurality of second pocket portions, each of the plurality of second pocket portions having an upper receiving space for receiving an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, wherein the plurality of second pocket portions and the second connecting portion are integrally formed; wherein the lower case and the upper case are mutually coupled by coupling the first connecting portion and the second connecting portion.

[0007] In exemplary embodiments, the first connecting portion is characterized in that it extends in a second direction intersecting the first direction from one end to the other end of the first pocket portion, and the second connecting portion is characterized in that it extends in the second direction from one end to the other end of the second pocket portion.

[0008] In exemplary embodiments, the first connecting portion includes a flat upper surface, the second connecting portion includes a flat lower surface, and the upper surface of the first connecting portion is characterized in that it contacts the lower surface of the second connecting portion.

[0009] In exemplary embodiments, the invention further comprises a bonding layer interposed between the first connecting portion and the second connecting portion.

[0010] In exemplary embodiments, the bonding layer is characterized by comprising a metal.

[0011] In exemplary embodiments, the lower case further includes a first flange extending from a first pocket portion that is outermost among the plurality of first pocket portions, and the upper case further includes a second flange extending from a second pocket portion that is outermost among the plurality of second pocket portions, wherein the first flange is coupled to the second flange.

[0012] In exemplary embodiments, the first flange extends in a second direction intersecting the first direction from one end of the first pocket portion to the other end, the second flange extends in the second direction from one end of the second pocket portion to the other end, the first flange includes a flat upper surface, the second flange includes a flat lower surface, and the upper surface of the first flange is in contact with the lower surface of the second flange.

[0013] In exemplary embodiments, the first flange and the second flange are characterized in that they are joined by a metal bonding layer.

[0014] In exemplary embodiments, each of the plurality of first pockets is characterized by including a first cooling channel.

[0015] In exemplary embodiments, each of the plurality of second pockets is characterized by including a second cooling channel.

[0016] In exemplary embodiments, in each of the plurality of battery cell assemblies, the plurality of battery cells are characterized in that they are stacked in the first direction.

[0017] In order to solve the above-described problem, the technical idea of ​​the present invention provides a battery pack including: a pack housing; and a battery module accommodated in the pack housing; wherein the battery module comprises: a plurality of battery cell assemblies, each battery cell assemblies including a plurality of battery cells; a lower case, each of the plurality of first pocket portions spaced apart from each other in a first direction and a first connecting portion extending between two adjacent first pocket portions among the plurality of first pocket portions, wherein the plurality of first pocket portions each have a lower receiving space for accommodating a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, wherein the plurality of first pocket portions and the first connecting portion are integrally formed; and an upper case, each of the plurality of second pocket portions spaced apart from each other in the first direction and a second connecting portion between two adjacent second pocket portions among the plurality of second pocket portions, wherein the plurality of second pocket portions each have an upper receiving space for accommodating an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, wherein the plurality of second pocket portions and the second connecting portion are integrally formed; wherein the lower case and the upper case are mutually coupled by coupling the first connecting portion and the second connecting portion.

[0018] In exemplary embodiments, the battery module is spaced apart from the bottom plate of the pack housing, and a space is provided between the battery module and the bottom plate of the pack housing.

[0019] In exemplary embodiments, the pack housing is characterized by including a support structure that supports the combination of the first connecting portion and the second connecting portion.

[0020] In exemplary embodiments, the lower case further includes a first flange extending from a first pocket portion that is outermost among the plurality of first pocket portions, the upper case further includes a second flange extending from a second pocket portion that is outermost among the plurality of second pocket portions, the first flange being coupled to the second flange, and the pack housing including a support structure that supports the combination of the first flange and the second flange.

[0021] According to exemplary embodiments of the present invention, the upper case and the lower case, which are structures for accommodating and supporting a plurality of battery cell assemblies, are each formed as an integral press, thereby simplifying the manufacturing process of the battery module and reducing the manufacturing cost of the battery module. Furthermore, since the accommodating spaces provided by the upper case and the lower case can accommodate a plurality of battery cell assemblies, a larger battery module can be achieved.

[0022] Furthermore, according to exemplary embodiments of the present invention, the lower case and the upper case have a relatively large bonding area, thereby securing a wide weldable area during the welding process for joining the lower case and the upper case. Accordingly, the manufacturing process of the battery module can be made easier.

[0023] Furthermore, according to exemplary embodiments of the present invention, the battery module has a relatively wide contact area with the support structure of the pack housing, so that stress applied to the fastening portion of the battery module and the pack housing can be distributed, thereby reducing damage to the fastening portion of the battery module and the pack housing. Accordingly, the safety and reliability of the battery pack can be improved.

[0024] The effects that can be obtained from the exemplary embodiments of the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of the present disclosure pertain from the following description. In other words, unintended effects resulting from practicing the exemplary embodiments of the present disclosure can also be derived by those skilled in the art from the exemplary embodiments of the present disclosure.

[0025] FIG. 1 is an exploded perspective view showing a battery module according to exemplary embodiments of the present invention.

[0026] FIG. 2 is a plan view showing a battery module according to exemplary embodiments of the present invention.

[0027] FIG. 3 is a cross-sectional view showing a battery module according to exemplary embodiments of the present invention.

[0028] FIG. 4 is an exploded view showing a battery module according to exemplary embodiments of the present invention.

[0029] FIG. 5 is a cross-sectional view showing a joint area between an upper case and a lower case of a battery module according to exemplary embodiments of the present invention.

[0030] FIG. 6 is a cross-sectional view showing a battery module according to exemplary embodiments of the present invention.

[0031] FIG. 7 is a cross-sectional view showing a battery pack according to exemplary embodiments of the present invention.

[0032] FIG. 8 is a schematic diagram showing an electric vehicle equipped with a battery pack according to exemplary embodiments of the present invention.

[0033] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, it should be noted that the terms and words used in this specification and claims should not be construed as limited to their conventional or dictionary meanings. Based on the principle that the inventor can appropriately define the concepts of terms to best explain his or her invention, they should be interpreted in a way that aligns with the technical spirit of the present invention.

[0034] Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that there may be various equivalents and modified examples that can replace them at the time of filing this application.

[0035] In addition, when describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description is omitted.

[0036] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or schematically illustrated for clearer explanation. Accordingly, the sizes and proportions of each component do not fully reflect the actual sizes or proportions.

[0037]

[0038] (Example 1)

[0039] FIGS. 1 to 5 are drawings illustrating a battery module (10) according to exemplary embodiments of the present invention. FIG. 1 is an exploded perspective view illustrating a battery module (10). FIG. 2 is a plan view illustrating a battery module (10). FIG. 3 is a cross-sectional view illustrating a battery module (10). FIG. 4 is an exploded view illustrating a battery module (10). FIG. 5 is a cross-sectional view illustrating a joint area between an upper case (300) and a lower case (200) of a battery module (10).

[0040] Referring to FIGS. 1 to 5, a battery module (10) may include a plurality of battery cell assemblies (100), a lower case (200), and an upper case (300).

[0041] A plurality of battery cell assemblies (100) may be arranged in a first direction (X direction). The plurality of cell assemblies may be spaced apart in the first direction (X direction). Although the battery module (10) is exemplified as including two battery cell assemblies (100), the number of battery cell assemblies (100) included in the battery module (10) is not limited thereto. For example, the battery module (10) may include two or more battery cell assemblies (100).

[0042] An individual battery cell assembly (100) may include a cell block (110). The cell block (110) may include a plurality of battery cells (111). An individual battery cell (111) is a basic unit of a lithium ion battery, i.e., a secondary battery. An individual battery cell (111) may include an electrode assembly, an electrolyte, and a cell case. The electrode assembly built into the cell case may include a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode. The electrode assembly may be either a jelly-roll type or a stack type depending on the assembly form. A jelly-roll type electrode assembly may include a winding structure of a positive electrode, a negative electrode, and a separator interposed therebetween. A stack type electrode assembly may include a plurality of sequentially stacked positive electrodes, a plurality of negative electrodes, and a plurality of separators interposed therebetween. The positive electrode may include a positive electrode current collector and a positive electrode active material. The negative electrode may include a negative electrode current collector and an negative electrode active material.

[0043] A plurality of battery cells (111) may be connected in series and / or in parallel. For example, a plurality of battery cells (111) may be connected in series with each other. For example, a plurality of battery cells (111) may also be connected in parallel with each other. For example, when a set of two or more battery cells (111) connected in parallel with each other is defined as a bank, one bank composed of two or more battery cells (111) connected in parallel with each other and another bank composed of two or more battery cells (111) connected in parallel with each other may be connected in series.

[0044] Each battery cell (111) may correspond to a pouch-type battery cell, a cylindrical battery cell, or a square battery cell. The electrode assembly of the pouch-type battery cell is housed in a pouch case including an aluminum laminate sheet. The electrode assembly of the cylindrical battery cell is housed in a cylindrical metal can. The electrode assembly of the square battery cell is housed in a square metal can.

[0045] In exemplary embodiments, each battery cell (111) corresponds to a pouch-type battery cell, and a plurality of battery cells (111) within one battery cell assembly (100) may be stacked one upon another in a first direction (X direction). In exemplary embodiments, in each battery cell assembly (100), the plurality of battery cells (111) correspond to pouch-type battery cells, each having a length along the first direction (X direction) that is smaller than a length along the second direction (Y direction), and the plurality of battery cells (111) may be stacked in the first direction (X direction).

[0046] When viewed from a plane, the cell block (110) may have a rectangular shape in which a length along the first direction (X direction) is smaller than a length along the second direction (Y direction). The cell block (110) may have first and second side surfaces that are opposite to each other in the first direction (X direction), front and back surfaces that are opposite to each other in the second direction (Y direction), and upper and lower surfaces that are opposite to each other in the third direction (Z direction).

[0047] A busbar frame on which a busbar is mounted may be arranged on each of the front and rear sides of the cell block (110). A plurality of busbars may be mounted on the busbar frame on the front side of the cell block (110), and a plurality of busbars may be mounted on the busbar frame on the rear side of the cell block (110). The battery cell assembly (100) may include an end plate (120) for covering the busbar frame connected to the front or rear side of the cell block (110).

[0048] The busbar may be connected to the electrode leads of the battery cells (111). For example, the busbar may be connected to the electrode leads of the battery cells (111) by welding. For example, the individual busbars may be inter-busbars that are connected to electrode leads of different battery cells (111) belonging to the cell block (110) to electrically connect different battery cells (111). For example, the individual busbars may be terminal busbars that electrically connect the battery cell assembly (100) to another external battery cell assembly (100) or another electrical device.

[0049] A battery cell assembly (100) may include a plurality of cell blocks (110). For example, as illustrated in FIG. 1, an individual battery cell assembly (100) may include two cell blocks (110) arranged in a second direction (Y direction) and electrically connected to each other.

[0050] The lower case (200) can support a plurality of battery cell assemblies (100). The lower case (200) can include a plurality of lower accommodation spaces (220) for accommodating the plurality of battery cell assemblies (100). Each lower accommodation space (220) can accommodate a lower portion of a corresponding battery cell assembly (100) among the plurality of battery cell assemblies (100). The number of lower accommodation spaces (220) provided in the lower case (200) can be equal to the number of battery cell assemblies (100). In exemplary embodiments, the lower case (200) can be a single piece and have the same material composition as a whole. For example, to manufacture the lower case (200), a single plate can be prepared, and press processing can be performed on the single plate to process the single plate to have a predetermined structure.

[0051] The lower case (200) may include a plurality of first pocket portions (210), a first connecting portion (230), and a first flange (240). The plurality of first pocket portions (210), the first connecting portion (230), and the first flange (240) may form one body.

[0052] A plurality of first pocket portions (210) may be spaced apart from each other in a first direction (X direction). Each first pocket portion (210) may have a lower receiving space (220) in which a lower portion of a corresponding battery cell assembly (100) is received. Each first pocket portion (210) may have a U-shape when viewed in cross section. Each first pocket portion (210) may include a bottom wall facing a lower surface of the battery cell assembly (100), and two lower side walls spaced apart in the first direction (X direction) with the battery cell assembly (100) interposed therebetween. One of the two lower side walls may extend continuously along a first edge of the bottom wall, and the other of the two lower side walls may extend continuously along a second edge of the bottom wall opposite the first edge. When viewed in plan, the bottom wall may have a square shape. In each first pocket portion (210), a lower receiving space (220) may be defined by the bottom wall and two lower side walls. A length of the lower receiving space (220) along the first direction (X direction) may be the same as a length of the bottom wall along the first direction (X direction), a length of the lower receiving space (220) along the second direction (Y direction) may be the same as a length of the bottom wall along the second direction (Y direction), and a length of the lower receiving space (220) along the third direction (Z direction) (or a depth of the lower receiving space (220)) may be the same as a length of the lower side wall along the third direction (Z direction).

[0053] The first connecting portion (230) may extend between two first pocket portions (210) that are adjacent in the first direction (X direction) among the plurality of first pocket portions (210). For example, the first connecting portion (230) may extend from the upper end of one of the two first pocket portions (210) to the upper end of the other of the two second pocket portions (310), thereby physically connecting the two first pocket portions (210). The first connecting portion (230) may have a rectangular plate shape. The first connecting portion (230) may have a rectangular shape when viewed from a plan view, and the upper surface of the first connecting portion (230) may be flat. The first connecting portion (230) can be continuously extended in the second direction (Y direction) from one end to the other end of the first pocket portion (210), and the length of the first connecting portion (230) along the second direction (Y direction) can be substantially the same as or similar to the length of the first pocket portion (210) along the second direction (Y direction).

[0054] The first flange (240) may be connected to the outermost first pocket portion (210) among the plurality of first pocket portions (210). For example, the lower case (200) may include one first flange (240) extending outwardly from the first pocket portion (210) located at the leftmost side among the plurality of first pocket portions (210) and one first flange (240) extending outwardly from the first pocket portion (210) located at the rightmost side among the plurality of first pocket portions (210). The first flange (240) may extend continuously in the second direction (Y direction) along the edge of the corresponding first pocket portion (210). The first flange (240) may have a rectangular flat plate shape. The first flange (240) may have a rectangular shape when viewed in plan, and the upper surface of the first flange (240) may be flat. The first flange (240) can be continuously extended in the second direction (Y direction) from one end to the other end of the first pocket portion (210), and the length of the first flange (240) along the second direction (Y direction) can be substantially the same as or similar to the length of the first pocket portion (210) along the second direction (Y direction).

[0055] The upper case (300) may be placed on the lower case (200). The upper case (300) may be coupled to the lower case (200) to cover the plurality of cell assemblies on the lower case (200). The upper case (300) may include a plurality of upper receiving spaces (320) for receiving a plurality of battery cell assemblies (100). Each upper receiving space (320) may receive an upper portion of a corresponding battery cell assembly (100) among the plurality of battery cell assemblies (100). The number of upper receiving spaces (320) provided in the upper case (300) may be equal to the number of battery cell assemblies (100), and the position of each upper receiving space (320) may vertically overlap with a corresponding lower receiving space (220) among the plurality of lower receiving spaces (220). In exemplary embodiments, the upper case (300) may be a single piece and may have the same material composition as a whole. For example, to manufacture the upper case (300), a single flat plate may be prepared, and press processing may be performed on the single flat plate to process the single flat plate to have a predetermined structure.

[0056] The upper case (300) may include a plurality of second pocket portions (310), a second connecting portion (330), and a second flange (340). The plurality of second pocket portions (310), the second connecting portion (330), and the second flange (340) may form an integral body.

[0057] A plurality of second pocket portions (310) may be spaced apart from each other in a first direction (X direction). Each second pocket portion (310) may have an upper receiving space (320) in which an upper portion of a corresponding battery cell assembly (100) is received. Each second pocket portion (310) may include an upper wall facing an upper surface of the battery cell assembly (100) and two upper side walls spaced apart in the first direction (X direction) with the battery cell assembly (100) therebetween. One of the two upper side walls may extend continuously along a first edge of the upper wall, and the other of the two upper side walls may extend continuously along a second edge of the upper wall opposite the first edge. When viewed in plan, the upper wall may have a rectangular shape. In each second pocket portion (310), the upper receiving space (320) may be defined by the upper wall and the two upper side walls. The length of the upper receiving space (320) along the first direction (X direction) may be the same as the length of the upper wall along the first direction (X direction), the length of the upper receiving space (320) along the second direction (Y direction) may be the same as the length of the upper wall along the second direction (Y direction), and the length of the upper receiving space (320) along the third direction (Z direction) (or the depth of the upper receiving space (320)) may be the same as the length of the upper side wall along the third direction (Z direction).

[0058] The second connecting portion (330) may extend between two second pocket portions (310) that are adjacent in the first direction (X direction) among the plurality of second pocket portions (310). For example, the second connecting portion (330) may extend from the lower end of one of the two second pocket portions (310) to the lower end of the other of the two second pocket portions (310), thereby physically connecting the two second pocket portions (310). The second connecting portion (330) may have a rectangular flat plate shape. The second connecting portion (330) may have a rectangular shape when viewed from a plan view, and the lower surface of the second connecting portion (330) may be flat. The second connecting portion (330) can extend continuously in the second direction (Y direction) from one end to the other end of the second pocket portion (310), and the length of the second connecting portion (330) along the second direction (Y direction) can be substantially the same as or similar to the length of the second pocket portion (310) along the second direction (Y direction). The lower surface of the second connecting portion (330) can be in surface contact with the upper surface of the first connecting portion (230). The contact between the first connecting portions (230) and the first connecting portions (230) can be continuous or discontinuous in the second direction (Y direction). The second connecting portion (330) can be coupled to the first connecting portion (230). The upper case (300) can be coupled to the lower case (200) by the second connecting portion (330) being coupled to the first connecting portion (230).

[0059] The second flange (340) may be connected to the outermost second pocket portion (310) among the plurality of second pocket portions (310). For example, the upper case (300) may include one second flange (340) extending outwardly from the second pocket portion (310) located at the leftmost side among the plurality of second pocket portions (310) and one second flange (340) extending outwardly from the second pocket portion (310) located at the rightmost side among the plurality of second pocket portions (310). The second flange (340) may extend continuously in the second direction (Y direction) along the edge of the corresponding second pocket portion (310). The second flange (340) may have a rectangular plate shape. The second flange (340) may have a rectangular shape when viewed in plan, and the lower surface of the second flange (340) may be flat. The second flange (340) can extend continuously in the second direction (Y direction) from one end to the other end of the second pocket portion (310), and the length of the second flange (340) along the second direction (Y direction) can be substantially the same as or similar to the length of the second pocket portion (310) along the second direction (Y direction). The contact between the second flange (340) and the first flange (240) can be continuous or discontinuous in the second direction (Y direction). The lower surface of the second flange (340) can be in surface contact with the upper surface of the first flange (240). The second flange (340) can be coupled to the first flange (240). The upper case (300) can be coupled to the lower case (200) by the second flange (340) being coupled to the first flange (240).

[0060] In exemplary embodiments, the lower case (200) and the upper case (300) may be joined to each other by welding. As illustrated in FIG. 5, a bonding layer (410), for example, a metal bonding layer containing metal, may be interposed between the lower case (200) and the upper case (300). The metal bonding layer may be a material layer formed by welding. In exemplary embodiments, the bonding layer (410) may be interposed between the upper surface of the first connecting portion (230) of the lower case (200) and the lower surface of the second connecting portion (330) of the upper case (300), and the first connecting portion (230) may be joined to the second connecting portion (330) by the bonding layer (410). At the interface between the first connecting portion (230) and the second connecting portion (330), the bonding layer (410) may extend continuously or discontinuously along the second direction (Y direction). In exemplary embodiments, a bonding layer (410) may be interposed between the upper surface of the first flange (240) of the lower case (200) and the lower surface of the second flange (340) of the upper case (300), and the first flange (240) may be bonded to the second flange (340) by the bonding layer (410). At the interface between the first flange (240) and the second flange (340), the bonding layer (410) may extend continuously or discontinuously along the second direction (Y direction).

[0061] In exemplary embodiments, the upper case (300) may have a cooling channel (311) configured to allow a cooling fluid to flow therethrough and configured to cool the battery cell assembly (100) so that the battery cell assembly (100) has an appropriate operating temperature. The cooling channel (311) may be provided within each of the plurality of second pocket portions (310) of the upper case (300). For example, the cooling channel (311) may be provided within an upper wall and / or an upper side wall of each of the second pocket portions (310). An externally provided cooling fluid may be introduced into the cooling channel (311) through an inlet of the cooling channel (311), flow along the cooling channel (311), and be discharged to the outside through an outlet of the cooling channel (311). While the cooling fluid flows along the cooling channel (311), cooling of the battery cell assembly (100) may be performed. In exemplary embodiments, a thermally conductive adhesive layer may be interposed between the upper case (300) and the battery cell assembly (100) to enhance thermal coupling between the upper case (300) and the battery cell assembly (100). The thermally conductive adhesive layer may include, for example, a thermal interface material (TIM). In this case, heat generated in the battery cell assembly (100) may be transferred to the upper case (300) through the thermally conductive adhesive layer.

[0062] According to exemplary embodiments of the present invention, the upper case (300) and the lower case (200), which are structures for accommodating and supporting a plurality of battery cell assemblies (100), are each formed as an integral press, thereby simplifying the manufacturing process of the battery module (10) and reducing the manufacturing cost of the battery module (10). In addition, since a plurality of battery cell assemblies (100) can be accommodated in the accommodation spaces provided by the upper case (300) and the lower case (200), an increase in the size of the battery module (10) can be achieved.

[0063] In addition, according to exemplary embodiments of the present invention, the lower case (200) and the upper case (300) have a relatively wide joining area, so that a wide weldable area can be secured during the welding process for joining the lower case (200) and the upper case (300). Accordingly, the manufacturing process of the battery module (10) can be made easier.

[0064]

[0065] (Example 2)

[0066] Fig. 6 is a cross-sectional view illustrating a battery module (10A) according to exemplary embodiments of the present invention. Hereinafter, the battery module (10A) illustrated in Fig. 6 will be described with a focus on differences from the battery module (10) described with reference to Figs. 1 to 5.

[0067] Referring to FIG. 6, in the battery module (10A), the lower case (200) may have a cooling channel (211) configured to allow a cooling fluid to flow, and may be configured to cool the battery cell assembly (100) so that the battery cell assembly (100) has an appropriate operating temperature. The cooling channel (211) may be provided within each of the plurality of first pocket portions (210) of the lower case (200). For example, the cooling channel (211) may be provided within the lower wall and / or the lower side wall of each of the first pocket portions (210). An externally provided cooling fluid may be introduced into the cooling channel (211) through an inlet of the cooling channel (211), flow along the cooling channel (211), and be discharged to the outside through an outlet of the cooling channel (211). In exemplary embodiments, a thermally conductive adhesive layer including a material such as TIM may be interposed between the lower case (200) and the battery cell assembly (100) to enhance thermal bonding between the lower case (200) and the battery cell assembly (100).

[0068] In exemplary embodiments, both the upper case (300) and the lower case (200) may include a cooling channel (211). That is, the upper case (300) may have a cooling channel (311) therein as illustrated in FIG. 3, and the lower case (200) may have a cooling channel (211) as illustrated in FIG. 6.

[0069]

[0070] (Example 3)

[0071] FIG. 7 is a cross-sectional view showing a battery pack (500) according to exemplary embodiments of the present invention.

[0072] Referring to FIG. 7, a battery pack (500) may include a pack housing (501) and a battery module (10) mounted on the pack housing (501). The battery pack (500) may include one or more battery modules (10) mounted on the pack housing (501). In FIG. 7, the battery pack (500) is exemplified as including the battery module (10) described with reference to FIGS. 1 to 5, but is not limited thereto and may also include the battery module (10A) described with reference to FIG. 6.

[0073] The pack housing (501) may include a lower housing (510) having a receiving space in which a battery module (10) is received, and a pack lid (520) coupled to the lower housing (510) to cover the lower housing (510) in which the battery module (10) is received. The receiving space of the lower housing (510) may be defined by a bottom plate (511) facing a lower surface of the battery module (10), and a side wall (513) positioned around the bottom plate (511). A plurality of support structures (515) for supporting the battery module (10) may be provided on the bottom plate (511) of the lower housing (510). The plurality of support structures (515) may be spaced apart from each other in a first direction (X direction), and each of the plurality of support structures (515) may extend in a second direction (Y direction). The length of each support structure (515) along the second direction (Y direction) may be equal to or greater than the length of the battery module (10) along the second direction (Y direction).

[0074] The battery module (10) can be mounted on the pack housing (501) in a side-mounting manner. A plurality of support structures (515) each extending in the second direction (Y direction) can be provided on the bottom plate of the pack housing (501), and the battery module (10) can be fastened to the plurality of support structures (515) by a fastening member such as a bolt (BT).

[0075] More specifically, the first connecting portion (230) of the lower case (200) and the second connecting portion (330) of the upper case (300) are combined to form a first assembly, and the first assembly is disposed on a corresponding support structure (515) among a plurality of support structures (515), and the first assembly can be fastened to the corresponding support structure (515) by a bolt (BT). The support structure (515) can be continuously brought into contact with the first assembly in a second direction (Y direction). Since the support structure (515) and the first assembly can have a relatively wide contact area, the battery module (10) can be stably supported by the support structure (515).

[0076] In addition, the first flange (240) of the lower case (200) and the second flange (340) of the upper case (300) are combined to form a second assembly, and the second assembly is disposed on a corresponding support structure (515) among a plurality of support structures (515), and the second assembly can be fastened to the corresponding support structure (515) by a bolt (BT). The support structure (515) can be continuously in contact with the second assembly in a second direction (Y direction). Since the support structure (515) and the second assembly can have a relatively wide contact area, the battery module (10) can be stably supported by the support structure (515).

[0077] When the battery pack (500) is mounted on a vehicle, a cabin room for passengers may be located on the upper side of the pack lid (520), and the ground on which the vehicle runs may be located on the lower side of the lower housing (510).

[0078] The battery module (10) may be supported on a support structure (515) provided on the bottom plate (511) of the lower housing (510) in a side-mounted manner, and a free volume (FV) may be provided between the bottom plate (511) of the lower housing (510) and the battery module (10) so that the bottom plate (511) of the lower housing (510) and the battery module (10) are spaced apart in a third direction (Z direction). Through the free volume (FV), gas and flame generated in a thermal runaway situation can move. That is, the free volume (FV) becomes a venting passage through which high-temperature gas and flame can move.

[0079] In addition, even when a foreign substance is thrown to the bottom of the vehicle and a strong impact occurs in a hard ground driving situation such as an unpaved road, the impact can be absorbed through the free volume (FV). Therefore, the battery module (10) can be prevented from being damaged by the impact. The free volume (FV) can be understood as an empty space between the battery module (10) and the lower housing (510). When the lower housing (510) is deformed toward the battery module (10) due to an impact applied to the bottom of the vehicle, the free volume (FV) can freely allow the deformation of the lower housing (510) to a certain extent.

[0080] The height of the free volume (FV) and the distance between the bottom plate (511) of the lower housing (510) and the battery module (10) can be set sufficiently to absorb external impact. The height of the free volume (FV) can be determined by considering the dimensions and rigidity of the vehicle frame, the dimensions and rigidity of the lower housing (510), the dimensions of the battery pack (500), the amount of gas generated and the discharge speed during thermal runaway, etc. For example, when the thickness or rigidity of the bottom plate (511) of the vehicle frame or the lower housing (510) is relatively large, at least one of the size and height of the free volume (FV) can be relatively reduced. In addition, when the thickness or rigidity of the bottom plate (511) of the vehicle frame or the lower housing (510) is relatively small, the possibility of deformation of the bottom plate (511) of the lower housing (510) is high, and therefore, at least one of the size and height of the free volume (FV) can be relatively increased to protect the battery module (10). In addition, when the size of the battery pack (500) is relatively large due to the battery pack (500) specifications, a relatively large free volume (FV) can be secured. When the size of the battery pack (500) is relatively small, the height of the free volume (FV) that can be secured may be relatively small, and the thickness and rigidity of the bottom plate (511) of the lower housing (510) may need to be relatively increased. In addition, when the height of the free volume (FV) is too small, the gas discharge passage becomes small, and the pressure inside the battery pack (500) may rapidly increase in the event of thermal runaway. Therefore, the size and height of the free volume (FV) can be determined by considering the amount of gas generated and the discharge speed.

[0081] The maximum height of the free volume (FV) may be determined according to the damage tolerance of the battery cell (111) included in the battery module (10). For example, if the damage tolerance of the battery cell (111) is 1 mm, the free volume (FV) may be determined such that the battery cell (111) is not deformed by more than 1 mm when the lower housing (510) is deformed and presses the lower surface of the battery cell (111). In this case, the amount of deformation of the lower housing (510) may vary depending on the thickness or rigidity of the lower housing (510). Therefore, the size or height of the free volume (FV) may be determined by considering both the damage tolerance of the battery cell (111) and the thickness and rigidity of the lower housing (510).

[0082] In exemplary embodiments, the upper surface of the battery module (10) may be in close contact with the lower surface of the pack lid (520). In exemplary embodiments, the battery module (10) may be suspended and supported by the pack lid (520). If there is a space between the battery module (10) and the pack lid (520), during thermal runaway, high-temperature gas may be introduced into the space between one battery module (10) and the pack lid (520), causing heat and flame to spread to another adjacent battery module (10), and the heat and flame may also be transmitted to the pack lid (520), potentially affecting the cabin room above the pack lid (520). Therefore, by making the upper surface of the battery module (10) and the lower surface of the pack lid (520) in close contact, gas or flame generated inside the battery pack (500) may be guided to the free volume (FV).

[0083] According to exemplary embodiments of the present invention, since the battery module (10) has a relatively wide contact area with the support structure (515) of the pack housing (501), stress applied to the fastening portion of the battery module (10) and the pack housing (501) can be distributed, and damage to the fastening portion of the battery module (10) and the pack housing (501) can be reduced. Accordingly, the safety and reliability of the battery pack (500) can be improved.

[0084]

[0085] (Example 4)

[0086] FIG. 8 is a schematic diagram showing an electric vehicle (1000) equipped with a battery pack (1100) according to exemplary embodiments of the present invention.

[0087] In Fig. 8, for simplicity, only the body frame (1200) forming the lower frame of the vehicle, and the battery pack (1100) and tires coupled to the body frame (1200) are shown. The battery pack (1100) may include the battery pack (500) described with reference to Fig. 7.

[0088] In a typical battery pack, a battery module is installed at the bottom of the pack housing of the battery pack. In embodiments, a free volume (see FV of FIG. 7) may be provided at the bottom of the battery module (10) of the battery pack (1100), and the space between the battery module (10) and the pack lid (520) may be either non-existent or very narrow. Accordingly, the gas generated from the battery module (10) may be prevented from being transmitted to the cabin room at the top of the vehicle, and the gas may be guided to the free volume (FV) provided in the battery module (10) and the pack housing (501) of the battery pack (1100). The gas may flow through the free volume (FV) and be discharged to the lower part of the vehicle through a gas exhaust unit installed in the battery pack (1100). In addition, according to the present embodiments, since a free volume (FV) is provided between the battery module (10) and the pack housing (501) within the battery pack (1100), the battery module (10) can be prevented from being damaged even if the pack housing (501) is deformed.

[0089] According to embodiments of the present invention, a battery pack (1100) and an electric vehicle (1000) equipped with the same can enhance passenger safety. Furthermore, the battery module (10), a core component, can be protected, and the durability of the battery pack (1100) and the electric vehicle (1000) can be improved.

[0090]

[0091] The present invention has been described in more detail through drawings and examples. However, the configurations described in the drawings or examples described in this specification are merely embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that various equivalents and modified examples may exist as of the time of this application.

Claims

1. A plurality of battery cell assemblies each comprising a plurality of battery cells; A lower case comprising a plurality of first pocket portions spaced apart from each other in a first direction and a first connecting portion extending between two adjacent first pocket portions among the plurality of first pocket portions, wherein each of the plurality of first pocket portions has a lower receiving space for receiving a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and wherein the plurality of first pocket portions and the first connecting portion are integrally formed; and An upper case comprising a plurality of second pocket portions spaced apart from each other in the first direction and a second connecting portion between two adjacent second pocket portions among the plurality of second pocket portions, wherein each of the plurality of second pocket portions has an upper receiving space for receiving an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and wherein the plurality of second pocket portions and the second connecting portion are integrally formed; Including, A battery module wherein the lower case and the upper case are mutually connected by the first connecting portion and the second connecting portion being connected.

2. In paragraph 1, The first connecting portion extends in a second direction intersecting the first direction from one end of the first pocket portion to the other end, A battery module characterized in that the second connecting portion extends in the second direction from one end of the second pocket portion to the other end.

3. In paragraph 2, The above first connecting portion includes a flat upper surface, The second connecting portion includes a flat lower surface, A battery module characterized in that the upper surface of the first connecting portion is in contact with the lower surface of the second connecting portion.

4. In paragraph 1, A battery module further comprising a bonding layer interposed between the first connecting portion and the second connecting portion.

5. In paragraph 4, A battery module characterized in that the bonding layer comprises a metal.

6. In paragraph 1, The lower case further includes a first flange extending from the first pocket portion which is the outermost of the plurality of first pocket portions, The upper case further includes a second flange extending from the second pocket portion which is the outermost of the plurality of second pocket portions, A battery module characterized in that the first flange is coupled to the second flange.

7. In paragraph 6, The first flange extends in a second direction intersecting the first direction from one end of the first pocket portion to the other end, The second flange extends in the second direction from one end of the second pocket portion to the other end, The above first flange includes a flat upper surface, The second flange includes a flat lower surface, A battery module characterized in that the upper surface of the first flange is in contact with the lower surface of the second flange.

8. In paragraph 6, A battery module characterized in that the first flange and the second flange are joined by a metal bonding layer.

9. In paragraph 1, A battery module, characterized in that each of the plurality of first pockets includes a first cooling channel.

10. In paragraph 1, A battery module characterized in that each of the plurality of second pockets includes a second cooling channel.

11. In paragraph 1, A battery module, characterized in that in each of the plurality of battery cell assemblies, the plurality of battery cells are stacked in the first direction.

12. Pack housing; and A battery module accommodated in the above pack housing; Including, The above battery module, A plurality of battery cell assemblies each comprising a plurality of battery cells; A lower case comprising a plurality of first pocket portions spaced apart from each other in a first direction and a first connecting portion extending between two adjacent first pocket portions among the plurality of first pocket portions, wherein each of the plurality of first pocket portions has a lower receiving space for receiving a lower portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and wherein the plurality of first pocket portions and the first connecting portion are integrally formed; and An upper case comprising a plurality of second pocket portions spaced apart from each other in the first direction and a second connecting portion between two adjacent second pocket portions among the plurality of second pocket portions, wherein each of the plurality of second pocket portions has an upper receiving space for receiving an upper portion of a corresponding battery cell assembly among the plurality of battery cell assemblies, and wherein the plurality of second pocket portions and the second connecting portion are integrally formed; Including, A battery pack wherein the lower case and the upper case are mutually connected by the first connecting portion and the second connecting portion being connected.

13. In paragraph 12, The above battery module is spaced apart from the bottom plate of the pack housing, A battery pack characterized in that a space is provided between the battery module and the bottom plate of the pack housing.

14. In paragraph 12, A battery pack characterized in that the pack housing includes a support structure that supports the combination of the first connecting portion and the second connecting portion.

15. In paragraph 12, The lower case further includes a first flange extending from the first pocket portion which is the outermost of the plurality of first pocket portions, The upper case further includes a second flange extending from the second pocket portion which is the outermost of the plurality of second pocket portions, The first flange is coupled to the second flange, A battery pack, characterized in that the pack housing includes a support structure that supports the combination of the first flange and the second flange.

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