Battery module with improved stability

Abstract

The present invention provides a battery module structure and a manufacturing method therefor, the structure comprising: a plurality of battery cells, each having a pair of electrode leads that protrude upward and being arranged in the width direction; a frame having an open upper side thereof and accommodating the plurality of battery cells; and an insulating resin filling at least a portion of the empty space between the plurality of battery cells and the frame.

Description

Battery modules with improved stability

[0001] This application claims the benefit of priority from Republic of Korea Patent Application No. 10-2024-0000582, dated January 2, 2024, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a structure of a battery module having improved structural and / or thermal stability and a method for manufacturing the same.

[0003] Secondary batteries, which boast high electrical properties such as high energy density and easy applicability across a wide range of product groups, are widely used not only in portable devices but also in electric or hybrid vehicles powered by electrical power sources, as well as in power storage devices. These batteries are attracting attention as a new energy source for environmental friendliness and energy efficiency, not only because they can dramatically reduce fossil fuel use, but also because they produce no byproducts from energy use.

[0004] While small mobile devices typically use one or two or three battery cells per device, medium- to large-sized devices, such as automobiles, require high output and large capacity. Therefore, medium- to large-sized battery modules, which electrically connect multiple battery cells, are used. Furthermore, these battery modules can be integrated into battery packs to achieve even higher output and capacity.

[0005] Figure 1 illustrates a pouch-type battery cell. Referring to this, a typical pouch-type battery cell (10) is configured by having a metal pouch encircle an electrode assembly, folded in half, and sealed. A pair of electrode leads (100) extend from the electrode assembly on both sides in the longitudinal direction and protrude outside the pouch, thereby electrically connecting the electrode assembly to the outside.

[0006] Figures 2 and 3 illustrate the structure of a conventional battery module. Referring to these, a conventional battery module (M) comprises a cell stack (1) in which a plurality of battery cells (10) are stacked, and a frame (2) for accommodating the cell stack. The frame (2) may have a U-shape with the front, rear, and upper sides open, and a bus bar connecting the electrode leads (100) to each other and a pair of end plates covering the bus bars are coupled to both sides in the longitudinal direction of the cell stack (1).

[0007] Meanwhile, the battery cell (10) generates a certain amount of heat during charging and discharging. Since heat accumulated in the battery cell (10) may affect the charging and discharging performance, it is necessary to dissipate this heat to the outside of the frame (2). To this end, the battery module (M) is applied on the bottom plate of the frame (2) and a resin (3) is applied that hardens after the cell stack (1) is placed thereon. The resin (3) includes a thermally conductive resin having high thermal conductivity.

[0008] Fig. 4 shows a cross-section of the battery module of Fig. 2. Referring to this, the resin (3) adhesively fixes the cell stack (1) on the bottom plate of the frame (2) and simultaneously conducts heat generated from the cell stack (1) to the frame (2) to dissipate heat.

[0009] However, since the resin (3) is connected only to the bottom of the cell stack (1), it may not be able to sufficiently dissipate heat generated in the cell stack (1), and may cause the cell stack (1) to not be fixed and to flow within the frame (2).

[0010] In particular, the battery cells (10) are at risk of ignition due to a short circuit or the like, so heat transmission between the battery cells (10) needs to be blocked. At this time, the resin (3) easily melts at high heat, which has the problem of damaging the structural thermal stability of the cell stack (1).

[0011] In addition, referring again to FIG. 3, the battery module (M) having the above structure has the disadvantages of low durability and inconvenient assembly as it is composed of a plurality of parts including the frame (2) of the housing and a pair of end plates.

[0012] The present invention was created under the background of the above-described prior art, and its purpose is to provide a structure of a battery module having excellent structural and / or thermal stability and a method for manufacturing the same.

[0013] Specifically, the present invention seeks to provide a structure of a battery module having excellent heat dissipation performance.

[0014] In addition, the present invention seeks to provide a structure of a battery module in which movement of battery cells within a frame is prevented.

[0015] Another technical challenge of the present invention is to provide a structure of a battery module that has excellent structural stability in a thermal runaway situation and blocks heat transmission between cells.

[0016] The present invention also aims to provide a structure of a battery module that is easy to manufacture and economical, a structure of a battery pack including the same, and / or a vehicle, and a method for manufacturing the same, in order to achieve the above-mentioned technical task.

[0017] The technical objectives of the present invention are not limited to the purposes mentioned above. Other objectives and advantages of the present invention not mentioned above can be understood through the following description and will be more clearly understood through the embodiments of the present invention. Furthermore, it will be readily apparent that the objectives and advantages of the present invention can be realized by the means and combinations thereof set forth in the claims.

[0018] In order to solve the above problem, the present invention provides a structure of a battery module including: a plurality of battery cells arranged in a width direction, each battery cell having a pair of electrode leads protruding upward; a frame that is open at the top and accommodates the plurality of battery cells; and an insulating resin that fills at least a portion of an empty space between the plurality of battery cells and the frame.

[0019] The resin is filled between the plurality of battery cells and the frame, insulating the plurality of battery cells and the frame while simultaneously adhesively fixing the plurality of battery cells to prevent movement. Accordingly, the battery module can simultaneously have excellent insulation and structural stability.

[0020] The above resin may include an insulating and adhesive resin to have excellent adhesive and insulating properties. For example, the above resin may include a silicone resin.

[0021] The resin may include at least one of a phase change material and a thermally conductive resin. Accordingly, the resin may absorb and dissipate heat generated from the battery cell. For example, the resin may include paraffin.

[0022] The resin may include a flame-retardant material. Accordingly, the resin may maintain its structure without completely melting even under high temperatures resulting from thermal runaway of the battery cell. Consequently, the stability of the battery module may be enhanced even in thermal runaway situations. For example, the resin may include aluminum hydroxide.

[0023] The battery module may further include a mounting member that is arranged on the bottom surface of the frame and on which the plurality of battery cells are mounted at a predetermined distance from each other. Accordingly, the plurality of battery cells can be mounted in an upright state with an appropriate distance between them within the frame before the resin is filled.

[0024] Despite its name, the above-mentioned support member may be a separate member placed on the bottom surface of the frame, or may refer to the shape of the bottom surface of the frame itself.

[0025] The above-mentioned mounting member may include at least one material selected from the group consisting of a phase change material and a thermally conductive resin. Accordingly, the mounting member may absorb and dissipate heat generated from the battery cell. For example, the mounting member may include paraffin.

[0026] The above-mentioned mounting member may include a flame-retardant material. Accordingly, the mounting member may maintain its structure without completely melting even under high temperatures resulting from thermal runaway of the battery cells. Accordingly, the stability of the plurality of battery cells may be enhanced even in a thermal runaway situation. For example, the mounting member may include an aluminum hydroxide material.

[0027] The resin may be configured to fill the space between at least one pair of battery cells. Accordingly, the resin may perform at least one of the following functions: blocking heat transmission between the battery cells, fixing the battery cells, uniformizing the surface pressure applied to the battery cells in the width direction, and absorbing heat between the battery cells.

[0028] At least one of the plurality of battery cells may have a tapered portion at its upper end that becomes narrower as it goes upward. The tapered portion may not receive pressure in the stacking direction when the one battery cell is stacked together with other battery cells. In this case, the upper end of the resin is positioned above the height at which the tapered portion begins, so that a surface pressure may be applied to the tapered portion, thereby making the surface pressure received by the battery cell constant.

[0029] The upper portion of the above resin may be positioned higher than the upper portions of the plurality of battery cells excluding the electrode leads. In this case, the resin can apply uniform pressure to the upper portions of the battery cells while simultaneously fixing them, and absorb heat emitted upward from the battery cells.

[0030] The lower portion of the resin may be positioned lower than the lower portions of the plurality of battery cells. Accordingly, fixation, insulation, and / or thermal conductivity between the battery cells and the bottom surface of the frame may be improved.

[0031] The above battery module may further include a resin cover covering the exposed upper surface of the resin. By providing the resin cover, overflow or unexpected deformation of the resin can be prevented before the resin is cured.

[0032] According to one embodiment of the present invention, the upper portion of the resin may be positioned lower than the upper portions of the plurality of battery cells, and accordingly, the resin cover may be provided with a plurality of holes arranged in the width direction and through which the plurality of battery cells pass vertically. The plurality of battery cells may be more firmly fixed while maintaining an appropriate spacing from each other by being fitted into the holes.

[0033] The battery module may further include a busbar electrically connecting the electrode leads to each other above the plurality of battery cells. In this case, unlike the case where the busbar must be connected to both longitudinal sides of the battery cells, the busbar frame on which the busbar is installed can be formed as a single member, which is economical. If the resin cover is provided, the busbar can be installed even before the resin is cured.

[0034] The present invention also provides a battery pack having the battery module built in and a structure of a vehicle having the same built in.

[0035] The above battery modules may be integrated into a battery pack in multiple units to increase capacity and / or voltage. The battery pack may include a venting device capable of discharging gases and flames emitted when the battery module ignites to the outside. The battery pack may be incorporated into a vehicle as a power source. The vehicle may include an electric vehicle, a hybrid vehicle, and the like.

[0036] The present invention also provides a battery module manufacturing method for manufacturing the battery module, the method sequentially including the steps of: arranging the plurality of battery cells within the frame; and injecting the resin before curing within the frame.

[0037] According to the present invention, a simple and economical method for manufacturing a battery module is provided, in which the electrical, structural, and / or thermal stability of the battery module can be improved by the resin that fills the gap between the plurality of battery cells and the frame and hardens by itself.

[0038] The resin may be partially injected before the plurality of battery cells are arranged within the frame, and may be re-injected after the plurality of battery cells are arranged within the frame. Accordingly, sufficient resin may be interposed between the plurality of battery cells and the bottom surface of the frame.

[0039] When the battery module includes the mounting member, the step of arranging the plurality of battery cells within the frame may include: a step of arranging the mounting member on a bottom surface of the frame; and a step of arranging the plurality of battery cells on the mounting member.

[0040] The above battery module manufacturing method may further include: a step of waiting for curing of the resin; and a step of installing a bus bar that electrically connects the electrode leads to each other.

[0041] Alternatively, if the battery module includes the resin cover, the method for manufacturing the battery module may further include: a step of installing a resin cover that covers the exposed upper surface of the resin; and a step of installing a bus bar that electrically connects the electrode leads to each other. In this case, the bus bar can be installed without waiting for the resin to harden, which is efficient.

[0042] The present invention can provide a structure of a battery module having excellent structural and / or thermal stability and a method for manufacturing the same.

[0043] Specifically, the present invention can provide a structure of a battery module having excellent heat dissipation performance due to a large contact area between the battery cell and the resin.

[0044] In addition, the present invention seeks to provide a structure of a battery module in which movement of battery cells within a frame is prevented as the battery cells are fixed to the frame over a large area.

[0045] Another advantage of the present invention is that it is possible to provide a structure of a battery module that has excellent structural stability in a thermal runaway situation and blocks heat transmission between cells by providing a flame-retardant resin between battery cells.

[0046] The present invention can also provide a structure of a battery module and a method for manufacturing the same, which does not require a lot of man-hours for assembly and is economical because the materials are simple.

[0047] In addition, the present invention may have various other effects, which will be described in each embodiment, or the description of effects that can be easily inferred by a person skilled in the art will be omitted.

[0048] Figure 1 shows a pouch-type battery cell.

[0049] Figures 2 and 3 show the structure of a conventional battery module.

[0050] Figure 4 shows a cross-section of the battery module of Figure 2.

[0051] Figure 5 shows the structure of a battery module according to one embodiment of the present invention.

[0052] Figure 6 shows the structure of a battery cell according to one embodiment of the present invention.

[0053] Figure 7 illustrates a mounting member according to one embodiment of the present invention.

[0054] Figures 8 and 9 illustrate a mounting member according to one embodiment of the present invention installed on the bottom surface of the frame.

[0055] FIGS. 10 and 11 illustrate a frame on which a battery cell is mounted and a cross-section thereof according to one embodiment of the present invention.

[0056] Figures 12 and 13 show a battery module according to one embodiment of the present invention with the resin cover removed.

[0057] Fig. 14 illustrates a resin cover according to one embodiment of the present invention.

[0058] Figures 15 and 16 show a cross-section of the exterior of a battery module according to one embodiment of the present invention.

[0059] Figures 17 and 18 each illustrate a battery pack including a battery module according to one embodiment of the present invention and a vehicle including the same.

[0060] Figure 19 illustrates a method for manufacturing a battery module according to one embodiment of the present invention.

[0061] [Explanation of symbols]

[0062] 1: Cell stack

[0063] 10: Battery cell

[0064] 100: Electrode lead

[0065] 101: Tapered section

[0066] 2: Frame

[0067] 20: Absence of support

[0068] 200: Home

[0069] 3: Resin

[0070] 4: Resin cover

[0071] 40: Hall

[0072] M: Battery module

[0073] P: Battery pack

[0074] V: Car

[0075] The above-described objects, features, and advantages will be described in detail below with reference to the accompanying drawings, so that those skilled in the art can easily practice the technical idea of ​​the present invention. In describing the present invention, if it is determined that a detailed description of known technologies related to the present invention may unnecessarily obscure the gist of the present invention, a detailed description thereof will be omitted. Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used to indicate the same or similar components.

[0076] Although the terms "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are used solely to distinguish one component from another, and unless otherwise specified, a "first" component may also be a "second" component.

[0077] Throughout the specification, unless otherwise specifically stated, each element may be singular or plural.

[0078] Hereinafter, the phrase "any configuration is placed on (or below)" a component or "on (or below)" a component may mean that any configuration is placed in contact with the upper surface (or lower surface) of said component, and that other configurations may be interposed between said component and any configuration placed on (or below) said component.

[0079] Additionally, when it is described that a component is "connected," "coupled," or "connected" to another component, it should be understood that the components may be directly connected or connected to one another, but that other components may also be "interposed" between the components, or that each component may be "connected," "coupled," or "connected" through another component.

[0080] As used herein, singular expressions include plural expressions unless the context clearly dictates otherwise. In this application, terms such as "consisting of" or "comprising" should not necessarily be construed to include all of the components or steps described in the specification, and should be construed to mean that some of the components or steps may not be included, or that additional components or steps may be included.

[0081] Throughout the specification, when we refer to "A and / or B", this means A, B, or A and B, unless otherwise stated, and when we refer to "C to D", this means C or more and D or less, unless otherwise stated.

[0082] Hereinafter, a preferred embodiment of the present invention will be described with reference to the attached drawings.

[0083]

[0084] [Battery module and battery cell structure]

[0085] Hereinafter, with reference to FIGS. 5 to 8, the structure of a battery module and a battery cell included therein according to one embodiment of the present invention will be described in detail.

[0086] Fig. 5 illustrates the structure of a battery module according to one embodiment of the present invention. Referring to this, a battery module (M) according to one embodiment of the present invention includes a plurality of battery cells (10) arranged in the width direction, a frame (2) that is open at the top to accommodate the plurality of battery cells (10), and an insulating resin (3) that fills at least a portion of the empty space between the plurality of battery cells (10) and the frame (2).

[0087] The shape of the above frame (2) may include, but is not limited to, a rectangular box shape with an upper side substantially open.

[0088] Figure 6 illustrates the structure of a battery cell according to one embodiment of the present invention. Referring to this, the battery cell (10) may include an electrode assembly and a pouch that surrounds the electrode assembly and is folded in half and sealed. A pair of electrode leads (100) may extend from the electrode assembly and protrude outside the pouch.

[0089] According to the present embodiment, the pair of electrode leads (100) may protrude in the same direction from one end of the battery cell (10). Specifically, the pair of electrode leads (100) may protrude from one long side where the pouch is sealed.

[0090] Referring back to FIG. 5, the plurality of battery cells (10) can be accommodated in the frame (2) such that the electrode leads (100) face upward. According to one embodiment of the present invention, since the electrode leads (100) all protrude upward, the frame (2) can be formed as an integral body with an upper side open, rather than having a composite configuration such as including a U-shaped frame and a pair of end plates, thereby providing excellent sealing properties and structural stability.

[0091]

[0092] [Battery cell mounting structure]

[0093] Referring again to FIG. 5, the battery module (M) may additionally include a mounting member (20).

[0094] Hereinafter, with reference to FIGS. 7 to 11, a structure in which a battery cell according to one embodiment of the present invention is mounted within a frame will be described in detail.

[0095] Fig. 7 illustrates a mounting member according to one embodiment of the present invention. Referring to this, the mounting member (20) may include a plurality of grooves (200) that are sunken downward. The plurality of grooves (200) may extend in the longitudinal direction and be arranged in the width direction.

[0096] Figures 8 and 9 illustrate a mounting member according to one embodiment of the present invention installed on the bottom surface of a frame. Referring to these drawings, the mounting member (20) can be installed on the bottom surface of the frame (2).

[0097] According to one modified example, the mounting member (20) is not provided separately, and the bottom surface of the frame (2) itself may have a shape that includes a groove in which the battery cell (10) can be mounted.

[0098] Figures 10 and 11 illustrate a frame on which a battery cell is mounted and a cross-section thereof according to one embodiment of the present invention. Referring to these, the battery cell (10) can be mounted and supported by having its lower end inserted into the groove (200) until the frame (2) is filled with the resin (3). As the grooves (200) are arranged to be spaced apart from each other in the width direction, the battery cells (10) can also be mounted in an upright state spaced apart from each other in the width direction.

[0099] The above-mentioned mounting member (20) may include at least one material selected from the group consisting of a phase change material and a thermally conductive resin. Accordingly, the mounting member (20) may absorb and dissipate heat generated from the battery cell (10). For example, the mounting member (20) may include paraffin.

[0100] The above-mentioned mounting member (20) may include a flame-retardant material. Accordingly, the mounting member (20) may maintain its structure without completely melting even under high temperatures resulting from thermal runaway of the battery cell (10). Accordingly, the stability of the cell stack (1) may be improved even in a thermal runaway situation. For example, the mounting member (20) may include an aluminum hydroxide material.

[0101]

[0102] [Resin material and shape]

[0103] Referring back to FIG. 5, after the plurality of battery cells (10) are accommodated within the frame (2), at least a portion of the remaining space within the frame (2) may be filled with the resin (3). The resin (3) may be filled by injecting it into the frame (2) and curing it. However, the method by which the resin (3) is filled into the frame (2) is not limited thereto, and may be accommodated by partially immersing the plurality of battery cells (10) in the resin (3) after it is injected, or by various other methods such as foam filling.

[0104] The above resin (3) is filled between the plurality of battery cells (10) and the frame (2), and insulates the plurality of battery cells (10) and the frame (2) while simultaneously adhesively fixing them to prevent the plurality of battery cells (10) from moving. Accordingly, the battery module (M) can have excellent insulation and structural stability at the same time.

[0105] Hereinafter, with reference to FIGS. 12 and 13, the material and shape of the resin according to one embodiment of the present invention will be described in detail.

[0106] Figures 12 and 13 illustrate a battery module according to one embodiment of the present invention with the resin cover removed. Referring to this, the resin (3) may be provided to fill a space between at least one pair of battery cells (10). Accordingly, the resin (3) may perform at least one of the following functions: blocking heat transmission between the battery cells (10), fixing the battery cells (10), uniformizing the surface pressure received by the battery cells (10) in the width direction, and absorbing heat between the battery cells (10).

[0107] If the battery cell (10) is subjected to an uneven surface pressure in the stacking direction, the spacing between the electrodes built into the battery cell (10) and / or the distribution of the charged electrolyte may change, which may affect the performance of the battery cell (10). This may also cause a short circuit due to precipitation of the electrolyte. Therefore, it is necessary to ensure that the battery cell (10) is subjected to an even surface pressure in the stacking direction.

[0108] According to one embodiment of the present invention, at least one of the plurality of battery cells (10) may have a tapered portion (101) at its upper end, the width of which becomes narrower as it goes upward. The tapered portion (101) may not receive pressure in the stacking direction when the one battery cell is stacked together with other battery cells. At this time, the upper end of the resin (3) is positioned higher than the height at which the tapered portion (101) starts, thereby applying surface pressure to the tapered portion (101) to make the surface pressure received by the battery cell (10) constant.

[0109] According to one embodiment of the present invention, the upper portion of the resin (3) may be positioned lower than the upper portion of the plurality of battery cells (10).

[0110] In contrast, the upper portion of the resin (3) may be positioned higher than the upper portions of the plurality of battery cells (10) excluding the electrode leads (100). In this case, the resin (3) can apply uniform pressure to the upper portions of the plurality of battery cells (10) while simultaneously fixing them, and can absorb heat emitted upward from the plurality of battery cells (10).

[0111] According to one embodiment of the present invention, the lower portion of the resin (3) may be positioned lower than the lower portions of the plurality of battery cells (10). Accordingly, fixation, insulation, and / or thermal conductivity between the plurality of battery cells (10) and the bottom surface of the frame (2) may be improved.

[0112] Alternatively, the lower portion of the resin (3) may be aligned with or positioned higher than the lower portion of the plurality of battery cells (10).

[0113] The above resin (3) may include at least one material selected from the group consisting of a phase change material and a thermally conductive resin. Accordingly, the resin (3) may absorb and dissipate heat generated from the battery cell (10). For example, the resin (3) may include paraffin.

[0114] The above resin (3) may include a flame-retardant material. Accordingly, the resin (3) may maintain its structure without completely melting even under high temperatures resulting from thermal runaway of the battery cell (10). Accordingly, the stability of the battery module (M) may be improved even in a thermal runaway situation. For example, the resin (3) may include an aluminum hydroxide material.

[0115]

[0116] [Resin cover and busbar]

[0117] Referring again to FIG. 5, the battery module (M) may additionally include a resin cover (4) that covers the exposed upper surface of the resin (3).

[0118] Hereinafter, with reference to FIGS. 14 and 15, the shape of the resin cover and the installation of the bus bar according to one embodiment of the present invention will be described in detail.

[0119] Fig. 14 illustrates a resin cover according to one embodiment of the present invention. Referring to this, in the present embodiment, since the upper portion of the resin (3) is positioned lower than the upper portions of the plurality of battery cells (10), the exposed surface of the resin (3) can be formed except for the area where the battery cells (10) protrude. Accordingly, the resin cover (4) can be provided with a plurality of holes (40) through which the plurality of battery cells (10) pass upward and downward. Like the plurality of battery cells (10), the plurality of holes (40) can extend in the longitudinal direction and be arranged in the width direction.

[0120] Figures 15 and 16 illustrate a cross-section of the exterior of a battery module according to one embodiment of the present invention. Referring to these drawings, the resin cover (4) can be installed to cover the exposed surface of the resin (3). At this time, the plurality of battery cells (10) can be more firmly fixed while maintaining an appropriate spacing from each other by being fitted into the holes (40).

[0121] In one variation, the upper portion of the resin (3) may be provided above the upper portions of the plurality of battery cells (10) excluding the electrode leads (100), and the resin cover (4) may not have the hole (40) or may be configured such that only the electrode leads (100) pass through the hole (40).

[0122] According to this embodiment, as the resin cover (4) is provided, overflow or unexpected deformation of the resin (3) can be prevented before the resin (3) is cured.

[0123] The above battery module (M) may additionally include a bus bar (not shown) that electrically connects the electrode leads (100) to each other above the plurality of battery cells (10). The bus bar may be included in a bus bar frame provided above the plurality of battery cells (10) and / or the resin cover (4).

[0124] According to the present embodiment, since the resin cover (4) prevents overflow or deformation of the resin (3), the bus bar can be installed even before the resin (3) is cured. In addition, according to the present embodiment, since the electrode leads (100) all protrude upward, the bus bar frame can also be integrally provided upward instead of being provided as a pair at the front and rear of the battery module (M), making assembly simple and economical.

[0125] In one variation, the battery module (M) may not include the resin cover (4), and thus the busbar may be installed after the resin (3) has been cured.

[0126]

[0127] [Battery pack and vehicle structure]

[0128] Hereinafter, with reference to FIGS. 17 and 18, a structure of a battery pack accommodating a battery module according to one embodiment of the present invention and a vehicle incorporating the same will be described.

[0129] Figures 17 and 18 illustrate the structure of a battery pack accommodating a battery module according to one embodiment of the present invention and a vehicle incorporating the battery pack, respectively. Referring to these drawings, a plurality of battery modules (M) may be integrated to form a battery pack (P) in order to increase the capacity and / or voltage thereof. The battery pack (P) may include a venting device capable of discharging gases and flames emitted when the battery module (M) ignites to the outside. The battery pack (P) may be incorporated into a vehicle (V) as a power source. The vehicle (V) may include an electric vehicle, a hybrid vehicle, etc.

[0130]

[0131] [Method for manufacturing battery modules]

[0132] Hereinafter, with reference to FIG. 19, a method for manufacturing a battery module according to one embodiment of the present invention will be described in detail.

[0133] Fig. 19 illustrates a method for manufacturing a battery module according to one embodiment of the present invention. Referring to this, the method for manufacturing a battery module according to one embodiment of the present invention may sequentially include: a step (S1, S2) of arranging the plurality of battery cells (10) within the frame (2); and a step (S3) of injecting the resin (3) before curing within the frame (2).

[0134] According to the present invention, the electrical, structural, and / or thermal stability of the battery module (M) can be improved by the resin (3) that fills the gap between the plurality of battery cells (10) and the frame (2) and hardens, thereby providing a simple and economical method for manufacturing a battery module (M).

[0135] The above resin (3) may be partially injected before the plurality of battery cells (10) are arranged in the frame (2), and may be injected again after the plurality of battery cells (10) are arranged in the frame (2). In other words, the battery module manufacturing method may additionally include a step of applying a portion of the resin (3) to the bottom surface of the frame (2) before the step (S2) of arranging the plurality of battery cells (10) in the frame. Accordingly, a sufficient amount of resin (3) may be interposed between the plurality of battery cells (10) and the bottom surface of the frame (2).

[0136] According to one embodiment of the present invention, the step (S1, S2) of arranging the plurality of battery cells (10) within the frame (2) may include: a step (S1) of arranging a mounting member (20) on the bottom surface of the frame (2); and a step (S2) of mounting the plurality of battery cells (10) on the mounting member (20).

[0137] According to one embodiment of the present invention, the battery module manufacturing method may further include: a step (S4) of installing the resin cover; and a step (S5) of installing the bus bar. In this case, the bus bar can be installed without waiting for the resin (3) to harden, which is efficient.

[0138] In contrast, if the battery module (M) does not have the resin cover (4), the battery module manufacturing method may include a step of waiting for curing of the resin (3) before the step of installing the bus bar.

[0139]

[0140] It should be understood that the above-described embodiments are illustrative in all respects and not restrictive, and the scope of the present invention will be determined by the claims that follow, rather than by the detailed description set forth above. Furthermore, the meaning and scope of the claims that follow, as well as all possible modifications and variations derived from their equivalent concepts, should be construed as encompassing the scope of the present invention.

[0141] Although the present invention has been described with reference to the drawings exemplified above, it is to be understood that the present invention is not limited to the embodiments and drawings disclosed herein, and that various modifications may be made by those skilled in the art within the scope of the technical idea of ​​the present invention. Furthermore, even if the operational effects according to the configuration of the present invention have not been explicitly described while describing the embodiments of the present invention, it is natural that the effects predictable by the corresponding configuration should also be acknowledged.

Claims

1. A plurality of battery cells arranged in the width direction, each having a pair of electrode leads protruding upward; A frame having an open top and accommodating the plurality of battery cells; and Including an insulating resin that fills at least a portion of the empty space between the plurality of battery cells and the frame; At least one of the plurality of battery cells has a tapered portion at its upper end whose width becomes narrower as it goes upward, A battery module, wherein the upper part of the resin is positioned above the height at which the tapered part begins.

2. In claim 1, It further includes a mounting member that is placed on the bottom surface of the frame and on which the plurality of battery cells are mounted at a predetermined interval from each other. A battery module, wherein the lower portion of the battery cell and the mounting member are in direct contact with each other.

3. In claim 1, A battery module, wherein the resin comprises at least one material among a phase change material and a thermally conductive resin.

4. In claim 1, A battery module comprising the above resin and a flame retardant material.

5. In claim 2, A battery module, wherein the above-mentioned supporting member comprises at least one material among a phase change material and a thermally conductive resin.

6. In claim 2, A battery module wherein the above-mentioned mounting member comprises a flame retardant material.

7. In claim 1, A battery module, wherein the resin fills the space between at least one pair of battery cells.

8. In claim 1, A battery module, wherein the upper portion of the resin is positioned higher than the upper portions of the plurality of battery cells excluding the electrode leads.

9. In claim 1, A battery module, wherein the lower portion of the resin is positioned downward compared to the lower portions of the plurality of battery cells.

10. In claim 1, A battery module further comprising a resin cover covering the exposed upper surface of the resin.

11. In claim 10, The upper part of the above resin is positioned lower than the upper part of the plurality of battery cells, A battery module, wherein the resin cover is arranged in the width direction and has a plurality of holes through which the plurality of battery cells pass vertically.

12. In claim 1, A battery module further comprising a bus bar electrically connecting the electrode leads to each other above the plurality of battery cells.

13. A battery pack incorporating a battery module according to any one of claims 1 to 12.

14. A vehicle having a built-in battery pack of claim 13.

15. A battery module manufacturing method for manufacturing the battery module of claim 1, a step of arranging the plurality of battery cells within the frame; and A method for manufacturing a battery module, comprising sequentially injecting the resin before hardening into the frame.

16. In claim 15, A method for manufacturing a battery module, wherein the resin is partially injected before the plurality of battery cells are arranged within the frame, and is re-injected after the plurality of battery cells are arranged within the frame.

17. In claim 15, The above battery module further includes a mounting member on which the plurality of battery cells are mounted at a predetermined interval from each other, The step of arranging the plurality of battery cells within the frame comprises: A step of placing a mounting member on the bottom surface of the above frame; and A method for manufacturing a battery module, comprising: a step of mounting a plurality of battery cells on the mounting member; 18. In claim 15, a step of waiting for the curing of the above resin; and A method for manufacturing a battery module, further comprising: a step of installing a bus bar for electrically connecting the electrode leads to each other.

19. In claim 15, A step of installing a resin cover covering the exposed upper surface of the resin; and A method for manufacturing a battery module, further comprising: a step of installing a bus bar for electrically connecting the electrode leads to each other.

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