Battery pack and method for manufacturing same

Abstract

According to exemplary embodiments, the present invention comprises the steps of: placing a plurality of battery cell assemblies and an electronic component on a pack housing including a base plate, a center beam on the base plate, and first and second cross beams, wherein the center beam is perpendicular to both the first and second cross beams; and painting a refractory coating on the plurality of battery cell assemblies.

Description

Battery pack and method of manufacturing the same

[0001] The present invention relates to a battery pack and a method for manufacturing the same. This application claims the benefit of Korean Application No. 10-2024-0010445, filed January 3, 2024, and Korean Application No. 10-2024-0032767, filed March 7, 2024, which are incorporated herein by reference in their entirety.

[0002] 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.

[0003] The technological development trend for secondary batteries for mobility is improving energy density and safety. The safety of secondary batteries for mobility is crucial, as it directly impacts the lives of passengers. Safety in secondary batteries can be achieved through mechanical robustness, reliable electrical insulation, and delayed heat transfer in the event of thermal runaway.

[0004] The technical idea of ​​the present invention is to provide a battery pack with improved safety and a method for manufacturing the same.

[0005] According to exemplary embodiments of the present invention for solving the above-described problem, there is provided a method of arranging a plurality of battery cell assemblies and electrical components on a pack housing including a base plate, a center beam on the base plate, and first and second cross beams, wherein the center beam is perpendicular to each of the first and second cross beams, and a method of providing a refractory coating to the plurality of battery cell assemblies by painting.

[0006] In the step of providing a refractory coating to the plurality of battery cell assemblies, the refractory coating is provided together with the second cross beams.

[0007] A further step of bonding a mask covering the first cross beam and the electrical component to the pack housing is further included prior to providing the refractory coating to the plurality of battery cell assemblies.

[0008] In the step of providing the refractory coating to the plurality of battery cell assemblies, the refractory coating is not applied to the first cross beam and the electrical component.

[0009] The mask covers a first portion of the center beam and exposes a second portion of the center beam.

[0010] In the step of providing the refractory coating to the plurality of battery cell assemblies, when providing the refractory coating, the refractory coating is not applied to the first portion of the center beam.

[0011] In the step of providing the refractory coating to the plurality of battery cell assemblies, when providing the refractory coating, the refractory coating is applied to the second portion of the center beam.

[0012] According to exemplary embodiments, a battery pack is provided. The battery pack comprises: a pack housing including a base plate and side walls; a center beam on the base plate, the center beam extending in a first direction parallel to a mounting surface of the base plate; first and second cross beams on the base plate, each of the first and second cross beams extending in a second direction parallel to the mounting surface of the base plate and perpendicular to the first direction; a plurality of battery cell assemblies disposed on the base plate and isolated by the center beam and the first and second cross beams, each of the plurality of battery cell assemblies including a first integrated circuit assembly including a first integrated circuit electrically connected to the plurality of battery cells, a plurality of pads interposed between the plurality of battery cells, and a second integrated circuit assembly including a second integrated circuit spaced apart from the first integrated circuit assembly in the second direction and electrically connected to the plurality of battery cells; an electrical component interposed between the side wall and the first cross beams; The method comprises: first refractory coatings applied on the plurality of battery cells of each of the plurality of battery cell assemblies; second refractory coatings applied on the plurality of pads of each of the plurality of battery cell assemblies; third refractory coatings applied on the first integrated circuit assembly of each of the plurality of battery cell assemblies; and fourth refractory coatings applied on the second integrated circuit assembly of each of the plurality of battery cell assemblies.

[0013] Further comprising fifth refractory coatings applied on the second cross beams.

[0014] Each of the first to fifth refractory coatings comprises the same material.

[0015] Further comprising a sixth refractory coating applied on the center beam.

[0016] The center beam includes a second portion having the sixth refractory coating applied thereto and a first portion spaced apart from the second refractory coating, and the first portion is spaced apart from the second portion in the first direction.

[0017] According to exemplary embodiments of the present invention, a refractory coating may be applied to a plurality of battery cell assemblies, cross beams, and center beams of a battery pack. This prevents thermal runaway events from propagating to the surroundings, thereby enhancing the safety of the battery pack.

[0018] 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.

[0019] FIG. 1 is a flowchart illustrating a method for manufacturing a battery pack according to exemplary embodiments.

[0020] FIG. 2 is a plan view illustrating a method of manufacturing a battery pack according to exemplary embodiments.

[0021] Figure 3 is a cross-sectional view taken along the cutting line 2I-2I' of Figure 2.

[0022] FIG. 4 is a cross-sectional view showing a battery cell according to exemplary embodiments.

[0023] Figure 5 is an exploded perspective view of a battery cell according to exemplary embodiments.

[0024] FIG. 6 is a plan view illustrating a method of manufacturing a battery pack according to exemplary embodiments.

[0025] FIG. 7 is a plan view illustrating a method of manufacturing a battery pack according to exemplary embodiments.

[0026] Figure 8 is a cross-sectional view taken along the cutting line 7I-7I' of Figure 7.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] 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.

[0031]

[0032] (Embodiments 1 and 2)

[0033] FIG. 1 is a flowchart illustrating a method for manufacturing a battery pack according to exemplary embodiments.

[0034] FIG. 2 is a plan view illustrating a method of manufacturing a battery pack according to exemplary embodiments.

[0035] Figure 3 is a cross-sectional view taken along the cutting line 2I-2I' of Figure 2.

[0036] FIG. 4 is a cross-sectional view showing a battery cell according to exemplary embodiments.

[0037] Figure 5 is an exploded perspective view of a battery cell according to exemplary embodiments.

[0038] FIG. 6 is a plan view illustrating a method of manufacturing a battery pack according to exemplary embodiments.

[0039] FIG. 7 is a plan view illustrating a method of manufacturing a battery pack according to exemplary embodiments.

[0040] Figure 8 is a cross-sectional view taken along the cutting line 7I-7I' of Figure 7.

[0041] Referring to FIGS. 1 to 3, a plurality of battery cell assemblies (120) and electrical components (150) can be arranged on a pack housing (110) in P110.

[0042] The pack housing (110) may provide a space for mounting a plurality of battery cell assemblies (120) and electrical components (150). The pack housing (110) may include a base plate (111), side walls (112, 113, 114, 115), and a center beam (116). Cross beams (131, 133) may further be provided on the base plate (111).

[0043] Here, two directions substantially parallel to the mounting surface (111M) of the base plate (111) are defined as the X direction and the Y direction, and a direction substantially perpendicular to the mounting surface (111M) of the base plate (111) is defined as the Z direction. The X direction, the Y direction, and the Z direction may be substantially perpendicular to each other. The mounting surface (111M) may face the battery cell assemblies (120).

[0044] The base plate (111) and the side walls (112, 113) may each be provided by an extrusion process. The extrusion direction of each of the base plate (111) and the side walls (112, 113) may be the X direction. The side walls (114, 115) may also be provided by an extrusion process. The side walls (112, 113, 114, 115) may be substantially perpendicular to the base plate (111).

[0045] According to exemplary embodiments, the base plate (111) and side walls (112, 113) may be joined by friction stir welding. The base plate (111) may include a plurality of unit plates joined by friction stir welding.

[0046] The center beam (116) may extend in the X direction. The center beam (116) may be interposed between the side walls (112, 113). The center beam (116) may be included in a center plate, which is one of a plurality of unit plates that are friction stir welded to each other. Accordingly, the center beam (116) may be formed together with the center plate, and the center beam (116) may be a continuous element integrally formed with the center plate.

[0047] The base plate (111) may include a plurality of cooling channels. The plurality of cooling channels may provide passages for the movement of a coolant, such as water, for example. The plurality of cooling channels may be formed by an extrusion process. The plurality of cooling channels may extend in the X direction. The plurality of cooling channels may be spaced apart in the Y direction.

[0048] A plurality of battery cell assemblies (120) may be arranged on a base plate (111) of a pack housing (110). The base plate (111) may support the plurality of battery cell assemblies (120). Side walls (112, 113, 114, 115) may horizontally surround the plurality of battery cell assemblies (120). The side walls (112, 113, 114, 115) may protect the plurality of battery cell assemblies (120).

[0049] The center beam (116) and cross beams (131, 133) can isolate the plurality of battery cell assemblies (120) from each other. The plurality of battery cell assemblies (120) can be spaced apart in the Y direction with the center beam (116) therebetween. The center beam (116) can be interposed between the plurality of battery cell assemblies (120). The plurality of battery cell assemblies (120) can be spaced apart in the X direction with the cross beams (131) therebetween. The cross beams (131) can be interposed between the plurality of battery cell assemblies (120).

[0050] The arrangement of the plurality of battery cell assemblies (120) in FIG. 2 can be referred to as a 3 * 2 arrangement. The arrangement of the plurality of battery cell assemblies (120) disclosed in FIG. 2 is a non-limiting example and does not limit the technical idea of ​​the present invention in any sense. A person skilled in the art will be able to easily arrive at a plurality of battery cell assemblies (120) arranged in M ​​* N (wherein, M and N are each integers greater than or equal to 2) based on the description herein.

[0051] Each of the plurality of battery cell assemblies (120) may include a plurality of battery cells (121), pads (122), a first integrated circuit assembly (123), and a second integrated circuit assembly (124).

[0052] Referring to FIGS. 4 and 5, a battery cell (121) may include a cell case (121C), an electrode assembly (121EA), a positive terminal (121P), and a negative terminal (121N). The battery cell (121) may further include an electrolyte.

[0053] According to exemplary embodiments, the battery cell (121) may include one of a cylindrical battery cell, a prismatic battery cell, and a pouch-type battery cell. The electrode assembly of the cylindrical battery cell is housed in a cylindrical metal can. The electrode assembly of the prismatic battery cell is housed in a prismatic metal can. The electrode assembly of the pouch-type battery cell is housed in a pouch case including an aluminum laminate sheet. Hereinafter, the technical idea of ​​the present invention will be described based on an example in which the battery cell (121) is a pouch-type battery cell. However, a person skilled in the art will easily arrive at an example in which the battery cell (121) is one of a cylindrical battery cell and a prismatic battery cell based on the description herein.

[0054] The electrode assembly (121EA) may include a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode. The electrode assembly (121EA) may be either a jelly-roll type or a stack type. The jelly-roll type electrode assembly (121EA) may include a winding structure of a positive electrode, a negative electrode, and a separator interposed between them. The stack type electrode assembly (121EA) may include a plurality of sequentially stacked positive electrodes, a plurality of negative electrodes, and a plurality of separators interposed between them.

[0055] Each of the plurality of anodes of the electrode assembly (121EA) may include an anode tab (not shown). The anode tab (not shown) of each of the plurality of anodes of the electrode assembly (121EA) may be short-circuited with the anode terminal (121P). The anode tab (not shown) of each of the plurality of anodes of the electrode assembly (121EA) may be welded with the anode terminal (121P).

[0056] Each of the plurality of cathodes of the electrode assembly (121EA) may include a cathode tab (121NT). The cathode tab (121NT) of each of the plurality of cathodes of the electrode assembly (121EA) may be short-circuited with the cathode terminal (121N). The cathode tab (121NT) of each of the plurality of cathodes of the electrode assembly (121EA) may be welded with the cathode terminal (121N).

[0057] The cell case (121C) may include an inner resin layer, a metal layer, and an outer resin layer. An adhesive and a corrosion-preventing layer may further be provided between the inner resin layer and the metal layer and between the outer resin layer and the metal layer.

[0058] The inner resin layer may have heat-sealing properties and may be referred to as a sealant layer. The inner resin layer enables sealing of the cell case (121C). The inner resin layer may include a polyolefin-based resin, such as polypropylene (PP) and polyethylene (PE). The metal layer may include one of an alloy of iron, carbon, chromium, and manganese, an alloy of iron, chromium, and nickel, and aluminum. The metal layer may be a gas barrier. The metal layer may block the ingress and egress of gas from the cell case (121C). The outer resin layer may be a surface protection layer. The outer resin layer may include a material having wear resistance and heat resistance, such as a nylon resin.

[0059] The cell case (121C) may be provided by joining a first cell case (121C1) and a second cell case (121C2). The first cell case (121C1) may be substantially flat. The first cell case (121C1) may not include a receiving portion. The second cell case (121C2) may include a receiving portion (121R). The receiving portion (121R) may be formed by a pouch forming process. The receiving portion (121R) is a portion of the second cell case (121C2) formed into a bowl shape to receive the electrode assembly (121EA).

[0060] The terrace (121T) of the second cell case (121C2) may surround the receiving portion (121R). The terrace (121T) of the second cell case (121C2) may be joined to the edge of the first cell case (121C1), thereby providing a cell case (121C). The sealing portion (121CS) may be provided by joining the first and second cases (121C1, 121C2). That is, the sealing portion (121CS) may be a joining portion of the first and second cases (121C1, 121C2).

[0061] As in the example of Fig. 2, when the receiving portion is formed only in the second cell case (121C2) among the first and second cases (121C1, 121C2), the sealing portion (121CS) may be connected to the first main surface (121FS1). The sealing portion (121CS) may include a portion that forms a plane with the first main surface (121FS1).

[0062] The cell case (121C) may have an approximately rectangular parallelepiped shape, and the first main surface (121FS1) and the second main surface (121FS2) of the cell case (121C) may be widest surfaces of the cell case (121C). The first main surface (121FS1) and the second main surface (121FS2) may be substantially parallel to at least one of the electrode assembly (121EA) or the plurality of positive electrodes and the plurality of negative electrodes included in the electrode assembly (121EA). The first main surface (121FS1) and the second main surface (121FS2) may be opposite to each other. The first main surface (121FS1) and the second main surface (121FS2) may be substantially perpendicular to the X direction, but are not limited thereto.

[0063] An insulating tape (121I) may be applied on the positive terminal (121P) and the negative terminal (121N). The positive terminal (121P) and the negative terminal (121N) may protrude outside the cell case (121C). The positive terminal (121P) and the negative terminal (121N) may protrude in the Y direction from the cell case (121C). Accordingly, the resulting voltage and current of the battery cell (121) may be output through the positive terminal (121P) and the negative terminal (121N). The positive terminal (121P) may be a positive lead. The negative terminal (121N) may be a negative lead. The Y direction may be substantially perpendicular to the X direction.

[0064] Referring again to FIGS. 1 to 3, a plurality of battery cells (121) may be arranged in the X direction. The plurality of battery cells (121) may be joined by, for example, an adhesive.

[0065] A plurality of battery cells (121) may form a plurality of banks. For example, some (e.g., three) battery cells (121) may be connected in parallel to each other and form a bank. A plurality of banks may be connected in series. The resulting connection configuration of the plurality of battery cells (121) may be referred to as 3-parallel-16-series (3P-16S), but this is for illustrative purposes only and does not limit the technical spirit of the present invention in any way. The number of banks connected in series and the number of battery cells (121) included in the plurality of banks may be determined depending on the magnitude of voltage and current to be output from the battery cell assembly (120).

[0066] In this example, two banks can form a unit stack. The unit stacks can alternate with the pads (122). One of the pads (122) can be placed between two of the unit stacks, and one of the unit stacks can be placed between two of the pads (122).

[0067] Since the odd-numbered banks are connected in series with the even-numbered banks, the orientation of the battery cells (121) of the odd-numbered banks may be different from the orientation of the battery cells (121) of the even-numbered banks. The orientation of the battery cells (121) of the odd-numbered banks may be opposite to the orientation of the battery cells (121) of the even-numbered banks. That is, the orientation of the battery cells (121) of the odd-numbered banks rotated 180 degrees around the Z-axis may be the same as the orientation of the battery cells (121) of the even-numbered banks. Accordingly, the positive terminals (121P, see FIG. 5) of the battery cells (121) of the odd-numbered banks may be adjacent to the negative terminals (121N, see FIG. 5) of the battery cells (121) of the even-numbered banks, and the positive terminals (121P, see FIG. 5) of the battery cells (121) of the even-numbered banks may be adjacent to the negative terminals (121N, see FIG. 5) of the battery cells (121) of the odd-numbered banks.

[0068] The pads (122) can absorb swelling of the plurality of battery cells (121). Each of the pads (122) may include polyurethane (PU). Each of the pads (122) may include a refractory material such as silicone. As a non-limiting example, two of the banks may be interposed between adjacent pads (122).

[0069] The first integrated circuit assembly (123) may include an insulating frame, an integrated circuit, bus bars, sensing plates, sensing bars, temperature sensors, wiring, and an insulating cover. The second integrated circuit assembly (124) may include an insulating frame, an integrated circuit, sensing plates, temperature sensors, wiring, and an insulating cover.

[0070] The first and second integrated circuit assemblies (123, 124) may include physical and functional components for providing electrical connections between the plurality of battery cells (121), outputting the resulting voltages of the plurality of battery cells (121), and measuring voltages (or currents) of nodes within a circuit comprised of the plurality of battery cells (121).

[0071] The insulating frame may include an insulating material such as plastic. The insulating frame may cover the front of a plurality of battery cells (121). The insulating frame may support integrated circuits, bus bars, sensing plates, sensing bars, temperature sensors, and wiring.

[0072] The bus bars may be short-circuited to the positive leads (121P) of one or more battery cells (121) of a first bank and to the negative leads (121N) of one or more battery cells (121) of a last bank. The bus bars may be welded to the positive leads (121P) of one or more battery cells (121) of the first bank and to the negative leads (121N) of one or more battery cells (121) of the last bank. The resulting voltage of the plurality of battery cells (121) of the battery cell assembly (120) may be output through the bus bars. The bus bars may be fixed to an insulating frame.

[0073] The integrated circuit may be mounted on an insulating frame. The positive leads (121P) and negative leads (121N) welded to each other may form nodes within the battery cell assembly (120). The integrated circuit may be configured to measure the voltages of the nodes via sensing plates and sensing bars.

[0074] The sensing bars may include a conductive material. The sensing bars may have a rod-like shape. The sensing bars may be short-circuited to the bus bars. The sensing bars may be coupled to the bus bars. The voltage of the bus bars may be measured through the sensing bars.

[0075] Each of the plurality of sensing plates may have a patch shape or a pad shape. The plurality of sensing plates may include a conductive material. The plurality of sensing plates may be short-circuited to corresponding ones of the positive lead (121P) and the negative lead (121N) of the plurality of battery cells (121).

[0076] Each of the plurality of sensing plates can be connected to an integrated circuit. Through the plurality of sensing plates, the voltages of the plurality of nodes within the battery cell assembly (120) can be measured.

[0077] The temperature sensors may be configured to measure the temperature of multiple points of the battery cell assembly (120). The temperature sensors may be spatially distributed, thereby allowing the temperature distribution within the battery cell assembly (120) to be measured.

[0078] The insulating cover may include an insulating material, such as plastic. The insulating cover may be fitted to the insulating frame. The insulating cover may cover the integrated circuit, bus bars, sensing plates, sensing bars, and temperature sensors, thereby protecting the electrical components of the first and second integrated circuit assemblies.

[0079] Each of the plurality of battery cell assemblies may further include a Flexible Flat Cable (FFC) assembly configured to provide an electrical connection between the integrated circuit of the first integrated circuit assembly (123) and the integrated circuit of the second integrated circuit assembly (124). Accordingly, measurements, such as temperature and voltage, collected from the integrated circuit of the second integrated circuit assembly (124) may be transmitted to the integrated circuit of the first integrated circuit assembly (123) via the FFC assembly. Measurements, such as temperature and voltage, collected from the integrated circuit of the second integrated circuit assembly (124) may also be transmitted to the integrated circuit of the first integrated circuit assembly (123) via wireless communication.

[0080] The TIM layers (140) may be provided on the base plate (111) of the pack housing (110). The TIM layers (140) may be interposed between each of the plurality of battery cells (121) and the base plate (111). The TIM layers (140) may include a resin composition. The TIM layers (140) may be provided by a thermal resin application process. The TIM layers (140) may mediate heat transfer between each of the plurality of battery cells (121) and the base plate (111).

[0081] The electrical component (150) may be placed on an electrical component mounting area (EMR). The electrical component mounting area (EMR) may be a space between the cross beams (131) and the side walls (115). The electrical component mounting area (EMR) may be defined by the base plate (111), the side walls (112, 113, 116), and the cross beams (131).

[0082] The electrical component (150) may include, for example, a Battery Management System (BMS). The BMS may be configured to monitor, balance, and control the battery pack (100). Monitoring of the battery pack (100) may include measuring voltage and current of specific nodes within a plurality of battery cell assemblies (120) and measuring temperature of set locations within the battery pack (100). The battery pack (100) may include measuring instruments for measuring the voltage, current, and temperature described above.

[0083] Balancing of a battery pack (100) is an operation that reduces the deviation between multiple battery cell assemblies (120). Control of the battery pack (100) includes preventing overcharge, overdischarge, and overcurrent. Through monitoring, balancing, and control, the battery pack (100) can operate under optimal conditions, thereby preventing shortening of the lifespan of each of the multiple battery cell assemblies (120).

[0084] The electrical components (150) may include a cooling device, a PRA (Power Relay Assembly), and a safety plug, etc. The cooling device may include a cooling fan. The cooling fan may prevent overheating of each of the plurality of battery cell assemblies (120) by circulating air inside the battery pack (100). The PRA may be configured to supply or cut off power from the high-voltage battery to an external load (e.g., a vehicle motor). The PRA may protect the plurality of battery cell assemblies (120) and the external load (e.g., a vehicle motor) by cutting off power supply to the external load (e.g., a vehicle motor) in a situation where an abnormal voltage, such as a voltage surge, occurs.

[0085]

[0086] Next, referring to FIGS. 1, 2, and 6, at P120, the electrical component mounting area (EMR) may be masked. Masking the electrical component mounting area (EMR) may include bonding a mask (MSK) to the pack housing (110). The mask (MSK) may be in contact with the cross beams (131) and the side walls (112, 113, 116). The mask (MSK) may be bonded to the cross beams (131) and the side walls (112, 113, 116) by a mechanical method such as bolting, or may simply be placed on the cross beams (131) and the side walls (112, 113, 116). The mask (MSK) may cover the electrical component (150) on the electrical component mounting area (EMR).

[0087]

[0088] Next, referring to FIGS. 1 and 6 to 8, at P130, refractory coatings (160) can be formed on a plurality of battery cell assemblies (120), a center beam (116), and cross beams (133). Accordingly, a battery pack (100) can be provided.

[0089] Refractory coatings (160) can be formed by a coating machine (SD). The coating machine (SD) can be configured to provide a coating material. For example, the coating machine (SD) can include a plurality of nozzles configured to spray the coating material. The coating machine (SD) can provide the refractory coatings (160) in an X-direction scanning manner. The operation of the coating machine (SD) can be repeated multiple times, and the thickness of the refractory coatings (160) can be increased with each repetition. For example, when refractory coatings (160) having a thickness of about 10 μm are provided by one operation of the coating machine (SD), refractory coatings (160) having a thickness of about 40 μm can be provided through four operations.

[0090] The refractory coatings (160) may include a refractory material. The refractory coatings (160) may be provided by a spray-type coating agent. The refractory coatings (160) may also be provided by a paint-type coating agent. The refractory coatings (160) may be provided using a ceramic water-soluble coating agent. The refractory coatings (160) may be provided by any one of the following methods: spraying, painting, printing, vapor deposition, dipping, spin coating, roller coating, floating coating, curtain coating, sputtering, coextrusion, etc.

[0091] According to exemplary embodiments, the melting temperature and / or ignition point of the refractory coatings (160) may be about 300°C or higher. According to exemplary embodiments, the melting temperature and / or ignition point of the refractory coatings (160) may be about 600°C or higher. According to exemplary embodiments, the melting temperature and / or ignition point of the refractory coatings (160) may be about 1000°C or higher. According to exemplary embodiments, the melting temperature and / or ignition point of the refractory coatings (160) may be about 1500°C or higher.

[0092] According to exemplary embodiments, the thermal conductivity of the refractory coatings (160) may be about 20 W / mK or less. According to exemplary embodiments, the thermal conductivity of the refractory coatings (160) may be about 1 W / mK or less. According to exemplary embodiments, the thermal conductivity of the refractory coatings (160) may be about 0.3 W / mK or less. The thermal conductivity of the refractory coatings (160) described above may be measured at room temperature (about 25°C).

[0093] According to exemplary embodiments, the thickness of the refractory coatings (160) may range from about 10 μm to about 50 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be greater than or equal to about 15 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be greater than or equal to about 20 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be greater than or equal to about 25 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be less than or equal to about 100 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be less than or equal to about 90 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be less than or equal to about 90 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be less than or equal to about 80 μm. According to exemplary embodiments, the thickness of the refractory coatings (160) may be about 70 μm or less. According to exemplary embodiments, the thickness of the refractory coatings (160) may be about 60 μm or less. According to exemplary embodiments, the thickness of the refractory coatings (160) may be about 50 μm or less. According to exemplary embodiments, the thickness of the refractory coatings (160) may be about 40 μm or less. According to exemplary embodiments, the thickness of the refractory coatings (160) may be about 30 μm or less.

[0094] When the thickness of the refractory coatings (160) increases, the refractory performance of the refractory coatings (160) is improved, but since the thickness of the refractory structure (121F) increases, the energy density of the battery device including the battery cell (121), such as, for example, the battery cell assembly (120, see FIG. 7), is reduced. That is, the thickness of the refractory coatings (160) can be determined based on the energy density and refractory performance, which are in a trade-off relationship with each other. The thickness range of the refractory coatings (160) described above can prevent the thickness of the refractory structure (121F) from becoming excessively large, while at the same time providing sufficient refractory performance to the refractory structure (121F).

[0095] The battery pack (100) may further include a plurality of inter-busbars configured to electrically connect a plurality of battery cell assemblies (120). The plurality of battery cell assemblies (120) may be connected in series by the plurality of inter-busbars. Accordingly, the battery pack (100) may be configured to output a high voltage to an external load (e.g., a vehicle motor).

[0096] The battery pack (100) may further include a lead (170) coupled to the side walls (112, 113, 114, 115) of the pack housing (110). The lead (170) is omitted in FIG. 7 to illustrate a clear positional relationship between components of the battery pack (100). The lead (170) may cover components mounted inside the battery pack (100), such as a plurality of battery cell assemblies (120) and electrical components. The lead (170) may be fixed to the pack housing (110) by a mechanical coupling means, such as bolting.

[0097] The battery pack may further include exhaust devices coupled to the sidewalls (114, 115). Either of the sidewalls (114, 115) may include exhaust holes connected to the exhaust devices. The exhaust devices may be configured to delay thermal propagation by releasing high-temperature gas within the battery pack (100) to the outside when a thermal runway event occurs in the plurality of battery cell assemblies (120).

[0098] Here, thermal runaway of multiple battery cell assemblies (120) is a state in which temperature changes of multiple battery cell assemblies (120) further accelerate the temperature change, which is an uncontrollable positive feedback. Multiple battery cell assemblies (120) in a state of thermal runaway exhibit a rapid temperature increase and emit a large amount of high-pressure gas and combustion debris.

[0099] The cross beams (131) and electrical components (150) covered by the mask (MSK) may not be subjected to refractory coatings (160). Accordingly, electrical components (150) requiring precise operation may be prevented from malfunctioning due to the application of refractory coatings (160), and the reliability of the battery pack (100) may be improved.

[0100] The center beam (116) may include a first portion to which the refractory coatings (160) are not applied and a second portion to which the refractory coatings (160) are applied. The first portion of the center beam (116) may be on the electrical component mounting region (EMR). That is, the first portion of the center beam (116) may be between the side wall (115) and the first cross beams (131) in the X direction. The second portion of the center beam (116) may be interposed between the plurality of battery cell assemblies (120).

[0101] Refractory coatings (160) may be applied to each of the cross beams (133). The refractory coatings (160) may be applied to the upper portion of each of the cross beams (133). The refractory coatings (160) may be applied to the upper surface (133U) of each of the cross beams (133). The upper surface (133U) of each of the cross beams (133) may be substantially perpendicular to the Z direction. The refractory coatings (160) may also be applied to the upper portion of the side walls (113S) of each of the cross beams (133). The upper surface (133U) of each of the cross beams (133) may be substantially perpendicular to the X direction.

[0102] Each of the refractory coatings (160) applied on the plurality of battery cells (121) may be referred to as a first refractory coating. Each of the refractory coatings (160) applied on the plurality of pads (122) may be referred to as a second refractory coating. Each of the refractory coatings (160) applied on the first integrated circuit assembly (123) may be referred to as a third refractory coating. Each of the refractory coatings (160) applied on the second integrated circuit assembly (124) may be referred to as a fourth refractory coating. Each of the refractory coatings (160) applied on the second cross beams (133) may be referred to as a fifth refractory coating. Each of the refractory coatings (160) applied on the center beam (116) may be referred to as a sixth refractory coating. According to exemplary embodiments, the refractory coatings (160) applied to the plurality of battery cells (121), the plurality of pads (122), the first integrated circuit assembly (123), the second integrated circuit assembly (124), the center beam (116), and the second cross beams (133) can be formed simultaneously and can include the same material.

[0103] Refractory coatings (160) may be applied to each element of the plurality of battery cell assemblies (120). More specifically, the refractory coatings (160) may be applied to a portion (e.g., an upper portion) of each of the plurality of battery cells (121) and a portion (e.g., an upper portion) of each of the pads (122). The upper portions of each of the plurality of battery cells (121) and the upper portions of each of the pads (122) may face the lead (170).

[0104]

[0105] 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 step of arranging a plurality of battery cell assemblies and electrical components on a pack housing including a base plate, a center beam on the base plate, and first and second cross beams, wherein the center beam is perpendicular to each of the first and second cross beams, and A method for manufacturing a battery pack, comprising the step of providing a refractory coating to the plurality of battery cell assemblies by a painting method.

2. In paragraph 1, A method for manufacturing a battery pack, characterized in that, in the step of providing a refractory coating to the plurality of battery cell assemblies, the refractory coating is provided together with the second cross beams.

3. In paragraph 1, A method of manufacturing a battery pack, further comprising the step of bonding a mask covering the first cross beam and the electrical component to the pack housing before providing the refractory coating to the plurality of battery cell assemblies.

4. In paragraph 3, A method for manufacturing a battery pack, characterized in that, in the step of providing the refractory coating to the plurality of battery cell assemblies, the refractory coating is not applied to the first cross beam and the electrical component.

5. In paragraph 3, A method for manufacturing a battery pack, wherein the mask covers a first portion of the center beam and exposes a second portion of the center beam.

6. In paragraph 5, A method for manufacturing a battery pack, characterized in that, in the step of providing the refractory coating to the plurality of battery cell assemblies, when providing the refractory coating, the refractory coating is not applied to the first portion of the center beam.

7. In paragraph 5, A method for manufacturing a battery pack, characterized in that, in the step of providing the refractory coating to the plurality of battery cell assemblies, when providing the refractory coating, the refractory coating is applied to the second portion of the center beam.

8. Pack housing including base plate and side walls; As a center beam on the base plate, the center beam extends in a first direction parallel to the mounting surface of the base plate; As first and second cross beams on the base plate, each of the first and second cross beams extends in a second direction parallel to the mounting surface of the base plate and perpendicular to the first direction; A plurality of battery cell assemblies arranged on the base plate and isolated by the center beam and the first and second cross beams, each of the plurality of battery cell assemblies including a first integrated circuit assembly including a plurality of battery cells arranged in the first direction, a plurality of pads interposed between the plurality of battery cells, a first integrated circuit assembly electrically connected to the plurality of battery cells, and a second integrated circuit assembly including a second integrated circuit spaced apart from the first integrated circuit assembly in the second direction and electrically connected to the plurality of battery cells; A full-length component interposed between the side wall and the first cross beams; First refractory coatings applied on each of the plurality of battery cells of the plurality of battery cell assemblies; Second refractory coatings applied on the plurality of pads of each of the plurality of battery cell assemblies; Third refractory coatings applied on the first integrated circuit assembly of each of the plurality of battery cell assemblies; and A battery pack comprising fourth refractory coatings applied on the second integrated circuit assembly of each of the plurality of battery cell assemblies.

9. In paragraph 8, A battery pack further comprising fifth refractory coatings applied on the second cross beams.

10. In paragraph 9, A battery pack, characterized in that each of the first to fifth refractory coatings comprises the same material.

11. In paragraph 10, A battery pack further comprising a sixth refractory coating applied on the center beam.

12. In paragraph 10, The center beam includes a second portion to which the sixth refractory coating is applied and a first portion spaced apart from the second refractory coating, and the first portion is spaced apart from the second portion in the first direction, the battery pack.

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