Battery apparatus and electric vehicle including same

Abstract

The technical idea of the present invention provides a battery apparatus comprising: a base structure: a plurality of cell assemblies mounted on the base structure and each of the plurality of cell assemblies including a plurality of battery cells; and a top cover coupled to the base structure and including a pair of outer walls spaced apart from each other in a first direction and an upper plate covering the plurality of cell assemblies and having an upper cooling channel.

Description

Battery device and electric vehicle including same

[0001] The present invention relates to a battery device and an electric vehicle including the same.

[0002] This application claims the benefit of priority to Republic of Korea Patent Application No. 10-2024-0013654, filed on January 30, 2024, and Republic of Korea Patent Application No. 10-2024-0148452, filed on October 28, 2024, all 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 problem to be solved by the present invention is to provide a battery device and an electric vehicle including the same.

[0006] In order to solve the above-described problem, the technical idea of ​​the present invention provides a battery device including a base structure; a plurality of cell assemblies mounted on the base structure, each cell assemblies including a plurality of battery cells; and a top cover coupled to the base structure and including a pair of outer walls spaced apart from each other in a first direction and an upper plate covering the plurality of cell assemblies and having an upper cooling channel.

[0007] In exemplary embodiments, the top cover further includes a center wall disposed between the pair of outer walls and extending from the upper plate toward the base structure, wherein some of the plurality of cell assemblies are spaced apart in the first direction with the center wall therebetween.

[0008] In exemplary embodiments, the invention further comprises a plurality of fastening bolts that connect the pair of outer walls and the central wall to the base structure.

[0009] In exemplary embodiments, the base structure is characterized by including a lower cooling channel.

[0010] In exemplary embodiments, the device further comprises: a lower inlet pipe coupled to the base structure and configured to deliver a first cooling fluid provided from the outside to an inlet of the lower cooling channel; a lower outlet pipe coupled to the base structure and configured to deliver the first cooling fluid provided from an outlet of the lower cooling channel to the outside; an upper inlet pipe coupled to the upper plate and configured to deliver a second cooling fluid provided from the outside to an inlet of the upper cooling channel; and an upper outlet pipe coupled to the upper plate and configured to deliver the second cooling fluid provided from an outlet of the upper cooling channel to the outside.

[0011] In exemplary embodiments, the base structure further comprises a separating wall extending in the first direction, wherein some of the plurality of cell assemblies are spaced apart in a second direction intersecting the first direction with the separating wall therebetween.

[0012] In exemplary embodiments, the separating walls each include a lower separating wall and an upper separating wall mounted on the lower separating wall, the upper separating wall being attached to a corresponding cell assembly among the plurality of cell assemblies, and the lower separating wall being spaced apart from a corresponding cell assembly among the plurality of cell assemblies with the upper separating wall interposed therebetween.

[0013] In exemplary embodiments, the device further comprises a thermal resin layer attached to each of the plurality of cell assemblies; and a tape disposed between the thermal resin layer and the base structure, wherein the tape includes a portion protruding outward from the thermal resin layer.

[0014] In exemplary embodiments, a portion of the tape is characterized by being interposed between one of the pair of outer walls and the base structure.

[0015] In exemplary embodiments, a surface of the base structure vertically overlapping one of the pair of outer walls is characterized as being coplanar with a surface of the base structure vertically overlapping one of the plurality of cell assemblies.

[0016] In exemplary embodiments, the base structure includes an inclined surface extending obliquely from a surface of the base structure that is vertically superimposed on one of the pair of outer walls to a surface of the base structure that is vertically superimposed on one of the plurality of cell assemblies, wherein the inclined surface of the base structure is in contact with the tape.

[0017] In exemplary embodiments, the plurality of cell assemblies are each characterized in that they are attached to the upper plate via a thermally conductive adhesive layer.

[0018] In exemplary embodiments, the device further comprises: a heat dissipation fin connected to the plurality of cell assemblies; and a thermally conductive adhesive layer attaching the heat dissipation fin to the upper plate.

[0019] In exemplary embodiments, the base structure includes a bottom plate supporting the plurality of cell assemblies and a center wall extending from the bottom plate toward the upper plate of the top cover, some of the plurality of cell assemblies being spaced apart in the first direction with the center wall therebetween, and further includes a fastening bolt fastening the center wall of the base structure to the upper plate of the top cover, the fastening bolt being characterized in that it penetrates the bottom plate, the center wall, and the upper plate.

[0020] In order to solve the above-described problem, the technical idea of ​​the present invention provides an electric vehicle including a vehicle frame; and a battery device connected to the vehicle frame, wherein the battery device includes a base structure having a lower cooling channel; a plurality of cell assemblies mounted on the base structure, each cell assemblies including a plurality of battery cells; and a top cover including a pair of outer side walls connected to the base structure and spaced apart in a first direction and an upper plate covering the plurality of cell assemblies and having an upper cooling channel; wherein the vehicle frame is connected to the top cover.

[0021] In exemplary embodiments, the vehicle frame includes a front frame having front wheels mounted thereon; and a rear frame having rear wheels mounted thereon and spaced apart from the front frame; wherein the pair of outer walls of the top cover include a front protrusion protruding forwardly from the base structure and a rear protrusion protruding rearwardly from the base structure, the front frame being coupled to the front protrusions of the pair of outer walls, and the rear frame being coupled to the rear protrusions of the pair of outer walls.

[0022] In exemplary embodiments, the top cover further includes a center wall disposed between the pair of outer walls and extending from the upper plate toward the base structure, wherein some of the plurality of cell assemblies are spaced apart in the first direction with the center wall therebetween.

[0023] In exemplary embodiments, the device further comprises: a plurality of fastening bolts connecting the pair of outer walls and the center wall to the base structure; a thermal resin layer attached to each of the plurality of cell assemblies; and a tape disposed between the thermal resin layer and the base structure.

[0024] In exemplary embodiments, the top cover is characterized by being a single integrated structure comprising the pair of outer side walls, the upper plate, and the center wall.

[0025] According to exemplary embodiments of the present invention, a battery device has a dual cooling structure that cools battery cells by using a base structure with a lower cooling channel and a top cover with an upper cooling channel, thereby improving cooling performance for the battery cells. Since heat generation in the battery device can be effectively controlled, the safety of the battery device can be improved.

[0026] According to exemplary embodiments of the present invention, a defective cell assembly can be easily separated from the frame and replaced with a normal cell assembly. Since the cell assembly can be separated unit by unit, maintenance costs of the battery device can be reduced.

[0027] 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.

[0028] FIG. 1 is a perspective view showing a battery device according to exemplary embodiments of the present invention.

[0029] Fig. 2 is a cross-sectional view of a battery device along line Ⅱ-Ⅱ' of Fig. 1.

[0030] Fig. 3 is a cross-sectional view of a battery device along line Ⅲ-Ⅲ' of Fig. 1.

[0031] Figures 4 and 5 are cross-sectional views each showing a portion of a battery device.

[0032] FIGS. 6A to 6C are plan views illustrating a method of manufacturing a battery device according to exemplary embodiments of the present invention.

[0033] FIGS. 7A and 7B are cross-sectional views illustrating a method for separating a cell assembly of a battery device according to exemplary embodiments of the present invention.

[0034] FIG. 8 is a plan view showing a battery device according to exemplary embodiments of the present invention.

[0035] FIGS. 9 and 10 are cross-sectional views showing a portion of a battery device according to exemplary embodiments of the present invention.

[0036] FIG. 11 is a cross-sectional view showing a portion of a battery device according to exemplary embodiments of the present invention.

[0037] FIG. 12 is a perspective view showing a battery device according to exemplary embodiments of the present invention.

[0038] FIG. 13 is a perspective view showing an electric vehicle according to exemplary embodiments of the present invention.

[0039] Fig. 14 is a perspective view showing a part of the electric vehicle illustrated in Fig. 13.

[0040] FIG. 15 is a perspective view illustrating a method for separating a cell assembly from an electric vehicle according to exemplary embodiments of the present invention.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045]

[0046] (Example 1)

[0047] Fig. 1 is a perspective view showing a battery device (10) according to exemplary embodiments of the present invention. Fig. 2 is a cross-sectional view of the battery device (10) taken along line II-II' of Fig. 1. Fig. 3 is a cross-sectional view of the battery device (10) taken along line III-III' of Fig. 1.

[0048] Referring to FIGS. 1 to 3, the battery device (10) may include a frame (100) and a plurality of cell assemblies (210) mounted within the frame (100).

[0049] An individual cell assembly (210) may include a plurality of battery cells (211). An individual battery cell (211) is a basic unit of a lithium ion battery, i.e., a secondary battery. An individual battery cell (211) 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 a negative electrode active material.

[0050] A plurality of battery cells (211) may be connected in series and / or in parallel. For example, a plurality of battery cells (211) may be connected in series with each other. For example, a plurality of battery cells (211) may also be connected in parallel with each other. For example, when a set of two or more battery cells (211) connected in parallel with each other is defined as a bank, one bank composed of two or more battery cells (211) connected in parallel with each other and another bank composed of two or more battery cells (211) connected in parallel with each other may be connected in series.

[0051] Each battery cell (211) 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.

[0052] In exemplary embodiments, the cell assembly (210) may include a plurality of battery cells (211) that are mutually stacked in a second horizontal direction (e.g., the Y direction). In the cell assembly (210), adjacent battery cells (211) among the plurality of battery cells (211) may be fixed to each other through an adhesive material, such as an adhesive tape. For example, the plurality of battery cells (211) may each correspond to a pouch-type battery cell in which a length along a first horizontal direction (e.g., the X direction) is greater than a length along a second horizontal direction (e.g., the Y direction). Each battery cell (211) may extend in the first horizontal direction (e.g., the X direction), and an electrode lead may be provided at at least one of both ends of each battery cell (211) along the first horizontal direction (e.g., the X direction). The electrode leads of adjacent battery cells (211) may be physically coupled.

[0053] When viewed from a plan view, the cell assembly (210) may have a rectangular shape. The cell assembly (210) may include upper and lower surfaces that are opposed to each other in a vertical direction (e.g., in the Z direction), first and second sides that are opposed to each other in a first horizontal direction (e.g., in the X direction), and third and fourth sides that are opposed to each other in a second horizontal direction (e.g., in the Y direction). The upper surface of the cell assembly (210) may include upper surfaces of a plurality of battery cells (211), and the lower surface of the cell assembly (210) may include lower surfaces of a plurality of battery cells (211).

[0054] The frame (100) may include a base structure (110), a top cover (130), and a separating wall (120).

[0055] The base structure (110) may generally have a flat plate shape extending in a first horizontal direction (e.g., X direction) and a second horizontal direction (e.g., Y direction). The base structure (110) may support a plurality of cell assemblies (210). A thermal resin layer (221) may be interposed between each of the plurality of cell assemblies (210) and the base structure (110). Each of the plurality of cell assemblies (210) may be physically and thermally coupled to the base structure (110) through the thermal resin layer (221). The thermal resin layer (221) may include, for example, a thermosetting resin and a thermally conductive filler.

[0056] The base structure (110) may include a lower cooling channel (119) configured to allow a first cooling fluid to flow. A lower inlet pipe (151) and a lower outlet pipe (153) may be coupled to the base structure (110). The lower inlet pipe (151) may transfer a first cooling fluid provided from the outside to the inlet of the lower cooling channel (119). The lower outlet pipe (153) may transfer the first cooling fluid provided from the outlet of the lower cooling channel (119) to the outside. The lower cooling channel (119) may include a first sub-channel extending in a first flow direction from the front to the rear of the frame (100), a second sub-channel extending in a second flow direction from the rear to the front of the frame (100), and a connecting channel connecting the first sub-channel and the second sub-channel and extending in a direction perpendicular to the first flow direction. The first cooling fluid may be introduced into the inlet of the lower cooling channel (119) through the lower inlet pipe (151), and may then sequentially flow along the first sub-channel, the connecting channel, the second sub-channel, and the lower outlet pipe (153). Cooling of the plurality of cell assemblies (210) may be achieved while the first cooling fluid flows. The first cooling fluid may include a coolant and / or a refrigerant. In exemplary embodiments, the individual battery cells (211) may be thermally coupled to the base structure (110) through a thermal resin layer (221). In some exemplary embodiments, the individual battery cells (211) may also be thermally coupled to the base structure (110) through a heat dissipation fin (see 215 of FIG. 5).

[0057] A top cover (130) may be coupled to a base structure (110) to cover a plurality of cell assemblies (210). The top cover (130) may include a pair of outer side walls (133), a center wall (135), and a top plate (131). The top cover (130) may be a single integrated structure comprising the pair of outer side walls (133), the center wall (135), and the top plate (131). In exemplary embodiments, a cross-section of the top cover (130) may have an inverted-double-U shape.

[0058] The upper plate (131) can cover a plurality of cell assemblies (210). The upper plate (131) can generally have a flat plate shape extending in a first horizontal direction (e.g., X direction) and a second horizontal direction (e.g., Y direction).

[0059] A pair of outer side walls (133) can be spaced apart in a first horizontal direction (e.g., X direction) with a plurality of cell assemblies (210) therebetween. Each outer side wall (133) can extend in a second horizontal direction (e.g., Y direction) and can extend in a vertical direction (e.g., Z direction) between the upper plate (131) and the base structure (110). Each outer side wall (133) can be fastened to an edge portion of the base structure (110) by a fastening bolt (161). A gasket (181) can be disposed between a bottom surface of each outer side wall (133) and an upper surface of the base structure (110). The fastening bolt (161) can be inserted into a hole of the base structure (110) and a hole of the gasket (181) and can be fastened to the outer side wall (133). The fastening bolt (161) can penetrate the base structure (110) in a vertical direction (e.g., in the Z direction) and partially penetrate the outer wall (133).

[0060] The length of each outer wall (133) along the second horizontal direction (e.g., Y direction) may be greater than the length of the base structure (110) along the second horizontal direction (e.g., Y direction). Each outer wall (133) may include a front protrusion (1331) protruding forward from the base structure (110) and a rear protrusion (1332) protruding rearward from the base structure (110).

[0061] The center wall (135) may include a center wall (135) disposed between a pair of outer walls (133) in a first horizontal direction (e.g., X-direction). The center wall (135) may extend in a second horizontal direction (e.g., Y-direction) and may extend in a vertical direction (e.g., Z-direction) from the upper plate (131) to the base structure (110). Some of the cell assemblies (210) among the plurality of cell assemblies (210) may be spaced apart from each other in the first horizontal direction (e.g., X-direction) with the center wall (135) therebetween. The center wall (135) may be fastened to the base structure (110) by a fastening bolt (162). The length of the center wall (135) along the second horizontal direction (e.g., Y direction) may be smaller than the length of the base structure (110) along the second horizontal direction (e.g., Y direction).

[0062] The top cover (130) may include an upper cooling channel (139) configured to allow a second cooling fluid to flow therethrough. The upper cooling channel (139) may be provided in the upper plate (131). In some exemplary embodiments, the upper cooling channel (139) may be provided in the center wall (135) and / or the outer wall (133) in addition to the upper plate (131). In FIG. 1, the upper cooling channel (139) is illustrated with dotted and dashed lines. An upper inlet pipe (155) and an upper outlet pipe (157) may be coupled to the upper plate (131). The upper inlet pipe (155) may transfer a second cooling fluid provided from the outside to the inlet of the upper cooling channel (139). The upper outlet pipe (157) may transfer a second cooling fluid provided from the outlet of the upper cooling channel (139) to the outside. The upper cooling channel (139) may include a first sub-channel extending in a first flow direction from the front to the rear of the frame (100), a second sub-channel extending in a second flow direction from the rear to the front of the frame (100), and a connecting channel connecting the first sub-channel and the second sub-channel and extending in a direction perpendicular to the first flow direction. A second cooling fluid may flow into the inlet of the upper cooling channel (139) through an upper inlet pipe (155) and then sequentially flow along the first sub-channel, the connecting channel, the second sub-channel, and the upper outlet pipe (157). Cooling of the plurality of cell assemblies (210) may be performed while the second cooling fluid flows. The second cooling fluid may include a cooling water and / or a refrigerant.

[0063] A separating wall (120) may be disposed on the base structure (110). The separating wall (120) may extend in a first horizontal direction (e.g., X direction) between a pair of outer walls (133). A separating wall (120) may be attached to each of two opposite side surfaces of an individual cell assembly (210) in a second horizontal direction (e.g., Y direction).

[0064] The partition wall (120) may include a lower partition wall (121) and an upper partition wall (123). The lower partition wall (121) may be fastened to the base structure (110). The upper partition wall (123) may be placed on the lower partition wall (121). The upper partition wall (123) may be fastened to the lower partition wall (121) via a fastening bolt (163). The upper partition wall (123) may be attached to a side of a corresponding cell assembly (210) among a plurality of cell assemblies (210). The lower partition wall (121) may be spaced apart from the corresponding cell assembly (210) with the upper partition wall (123) therebetween. An individual cell assembly (210) and two upper partition walls (123) attached to both sides of the cell assembly (210) may together form a single unit (see 201 of FIG. 7B).

[0065] According to exemplary embodiments of the present invention, the battery device (10) has a dual cooling structure that cools the battery cells (211) with a base structure (110) having a lower cooling channel (119) and a top cover (130) having an upper cooling channel (139), thereby improving the cooling performance of the battery cells (211). Since the heat generation of the battery device (10) can be effectively controlled, the safety of the battery device (10) can be improved.

[0066]

[0067] (Example 2)

[0068] Figures 4 and 5 are cross-sectional views each showing a part of a battery device (10).

[0069] Referring to FIG. 4, a thermally conductive adhesive layer (223) may be interposed between the cell assembly (210) and the upper plate (131) of the top cover (130). The battery cells (211) of the cell assembly (210) may be thermally and physically bonded to the upper plate (131) by the thermally conductive adhesive layer (223). For example, the thermally conductive adhesive layer (223) may include a thermal resin and / or a thermal interface material.

[0070] Referring to FIG. 5, the cell assembly (210) may include a plurality of heat dissipation fins (215) attached to battery cells (211). The plurality of heat dissipation fins (215) may be attached to a corresponding battery cell (211) among the plurality of battery cells (211) and may be attached to the upper plate (131) of the top cover (130) by a thermally conductive adhesive layer (223). The battery cells (211) may be thermally coupled to the upper plate (131) through the plurality of heat dissipation fins (215) and the thermally conductive adhesive layer (223). The plurality of heat dissipation fins (215) may include a material having excellent thermal conductivity, for example, aluminum, copper, gold, silver, or a combination thereof.

[0071]

[0072] (Example 3)

[0073] FIGS. 6A to 6C are plan views illustrating a method for manufacturing a battery device (10) according to exemplary embodiments of the present invention. Hereinafter, the method for manufacturing the battery device (10) described with reference to FIGS. 1 to 3 will be described with reference to FIGS. 6A to 6C together with FIGS. 1 to 3.

[0074] Referring to Fig. 6a, a base structure (110) is prepared, and lower separation walls (121) are bonded onto the base structure (110).

[0075] Referring to Fig. 6b, a thermal resin layer (221) is formed on the base structure (110). The thermal resin layer (221) can be formed by applying resin on the base structure (110).

[0076] Referring to FIG. 6c, a plurality of cell assemblies (210) are mounted on a base structure (110). Mounting individual cell assemblies (210) on the base structure (110) may include a step of preparing a unit (see 201 in FIG. 7b) having a cell assembly (210) and an upper separation wall (123) attached to both sides of the cell assembly (210), a step of positioning the unit (201) on the base structure (110) such that the lower surface of the cell assembly (210) contacts the thermal resin layer (221) and the upper separation wall (123) is seated on the lower separation wall (121), and a step of fastening the upper separation wall (123) and the lower separation wall (121) with fastening bolts (163).

[0077] Next, referring to FIG. 1, the top cover (130) is fastened to the base structure (110). To fasten the top cover (130) to the base structure (110), the top cover (130) is positioned on the base structure (110), and then the outer wall (133) is fastened to the base structure (110) with a fastening bolt (161), and the center wall (135) is fastened to the base structure (110) with a fastening bolt (162).

[0078]

[0079] (Example 4)

[0080] FIGS. 7A and 7B are cross-sectional views illustrating a method for separating a cell assembly (210) of a battery device (10) according to exemplary embodiments of the present invention. Hereinafter, a method for separating a cell assembly (210) of a battery device (10) described with reference to FIGS. 1 to 3 will be described with reference to FIGS. 7A and 7B together with FIGS. 1 to 3 .

[0081] Referring to FIG. 3 and FIG. 7a, the top cover (130) is separated from the base structure (110). To separate the top cover (130) from the base structure (110), the fastening bolt (161) is removed from the outer wall (133) and the base structure (110), and the fastening bolt (162) is removed from the center wall (135) and the base structure (110).

[0082] Referring to Fig. 7b, the fastening bolt (163) is removed from the separation wall (120) so that the upper separation wall (123) can be separated from the lower separation wall (121). Next, the unit (201) including the cell assembly (210) is lifted using a lifting mechanism, thereby separating the cell assembly (210) from the base structure (110).

[0083] According to exemplary embodiments of the present invention, a defective cell assembly (210) can be easily separated from a frame (100), and the defective cell assembly (210) can be exchanged for a normal cell assembly (210). According to exemplary embodiments of the present invention, since the cell assembly (210) can be separated in units, the maintenance cost of the battery device (10) can be reduced.

[0084]

[0085] (Example 5)

[0086] FIG. 8 is a plan view illustrating a battery device according to exemplary embodiments of the present invention. Below, the battery device illustrated in FIG. 8 will be described, focusing on differences from the battery device (10) described with reference to FIGS. 1 to 3.

[0087] Referring to FIG. 8, in the battery device, each of the battery cells (211a) of the cell assembly (210a) may be a cylindrical battery cell. The battery cells (211a) may be arranged in a horizontal direction (e.g., in the X direction and the Y direction) on the base structure (110).

[0088]

[0089] (Example 6)

[0090] FIGS. 9 and 10 are cross-sectional views illustrating portions of a battery device according to exemplary embodiments of the present invention. Below, the battery device illustrated in FIGS. 9 and 10 will be described, focusing on differences from the battery device (10) described with reference to FIGS. 1 to 3.

[0091] Referring to FIGS. 9 and 10, in the battery device, a tape (230) may be interposed between the base structure (110) and the thermal resin layer (221). The cell assembly (210) may be thermally and physically coupled to the base structure (110) through the thermal resin layer (221) and the tape (230). The tape (230) may include a substrate layer and an adhesive layer applied to at least one of the upper and lower surfaces of the substrate layer. For example, the tape (230) may be a double-sided tape.

[0092] In exemplary embodiments, the tape (230) may protrude outwardly from the thermal resin layer (221). A portion of the tape (230) may protrude outwardly from the cell assembly (210) and the thermal resin layer (221) without being covered by the cell assembly (210) and the thermal resin layer (221).

[0093] In exemplary embodiments, a portion of the tape (230) may be interposed between the outer wall (133) of the top cover (130) and the base structure (110). In some exemplary embodiments, the tape (230) may extend outward from the thermal resin layer (221) toward the outer wall (133), but may be spaced apart from the outer wall (133). In exemplary embodiments, a surface (114) of the base structure (110) that overlaps the outer wall (133) of the top cover (130) in a vertical direction (e.g., in the Z direction) may be coplanar with a surface (113) of the base structure (110) that overlaps the cell assembly (210) in a vertical direction (e.g., in the Z direction). The surface (114) of the base structure (110) that is overlapped in a vertical direction (e.g., in the Z direction) on the outer wall (133) of the top cover (130) and the surface (113) of the base structure (110) that is overlapped in a vertical direction (e.g., in the Z direction) on the cell assembly (210) may each be a flat surface.

[0094] In exemplary embodiments, a method of separating a cell assembly (210) of a battery device may include a step of removing a tape (230) after a step of separating a top cover (130) from a base structure (110). For example, after a portion of the tape (230) protruding from a thermal resin layer (221) is gripped by an extractor (310), the extractor (310) may be moved to remove the tape (230). At this time, the tape (230) may have sufficient tensile strength such that the tape (230) does not break while the extractor (310) pulls the tape (230) to remove the tape (230).

[0095] In a battery device according to a comparative example, a base to which a cell assembly is attached has an outer wall covering a side surface of the cell assembly, and a flat pack lead is attached to the outer wall of the base. In this case, even if the pack lead is removed, it is difficult to secure a working space for removing the tape interposed between the cell assembly and the base. In addition, since the tape removal path includes a curved path close to a right angle, there is a risk that stress will be concentrated on a specific portion of the tape during the tape removal operation, causing the tape to break.

[0096] According to exemplary embodiments of the present invention, by separating the top cover (130) from the base structure (110), a working space for extracting the tape (230) can be secured. In addition, since the tape (230) can be smoothly extracted along a extraction path of the tape (230) extending in a lateral direction (e.g., X direction), the occurrence of breakage of the tape (230) during the tape extraction operation can be prevented. Accordingly, the operation of separating a defective cell assembly (210) from the battery device can be made easier.

[0097]

[0098] (Example 7)

[0099] FIG. 11 is a cross-sectional view illustrating a portion of a battery device according to exemplary embodiments of the present invention. Below, the battery device illustrated in FIG. 11 will be described, focusing on differences from the battery device described with reference to FIGS. 9 and 10 .

[0100] Referring to FIG. 11, the base structure (110) may include an inclined surface (115) extending obliquely from a surface (113) of the base structure (110) that is vertically (e.g., in the Z direction) superimposed on the cell assembly (210) to a surface (114) of the base structure (110) that is vertically (e.g., in the Z direction) superimposed on an outer wall (133) of the top cover (130). The tape (230) may extend along the inclined surface (115) of the base structure (110). By separating the top cover (130) from the base structure (110), a working space for taking out the tape (230) is secured, so that the tape (230) can be smoothly taken out along the taking-out path of the tape (230) that extends laterally.

[0101]

[0102] (Example 8)

[0103] Fig. 12 is a perspective view illustrating a battery device (10A) according to exemplary embodiments of the present invention. Hereinafter, the battery device (10A) illustrated in Fig. 12 will be described, focusing on differences from the battery device (10) described with reference to Figs. 1 to 3.

[0104] Referring to FIG. 12, in the battery device (10A), the top cover (130A) may include a pair of outer side walls (133) and a top plate (131), and the base structure (110A) may include a bottom plate (111) and a center wall (112) that support a plurality of cell assemblies (210). The center wall (112) of the base structure (110A) may extend in a vertical direction (e.g., in the Z direction) from the bottom plate (111) to the top plate (131) of the top cover (130A). The center wall (112) may be between a pair of outer side walls (133) of the top cover (130A). The center wall (112) may extend in a second horizontal direction (e.g., in the Y direction) along the bottom plate (111). Some of the cell assemblies (210) may be spaced apart in a first horizontal direction (e.g., X-direction) with a center wall (112) therebetween.

[0105] The base structure (110A) can be fastened to the upper plate (131) of the top cover (130A) by a fastening bolt (168). The fastening bolt (168) can be inserted into a hole of the bottom plate (111), a hole of the center wall (112), and a hole of the top plate (131). The fastening bolt (168) can penetrate the bottom plate (111), the center wall (112), and the top plate (131) in a vertical direction (e.g., the Z direction). The fastening bolt (168) can include a protrusion protruding upward from the upper plate (131) of the top cover (130A), and a nut (169) can be coupled to the protrusion of the fastening bolt (168). By fastening the nut (169) to the protrusion of the fastening bolt (168), the connection between the upper plate (131) of the top cover (130A) and the center wall (112) of the base structure (110A) can be achieved. For example, when fastening the top cover (130A) and the base structure (110A), the fastening bolt (168) can be inserted into the hole of the bottom plate (111), the hole of the center wall (112), and the hole of the upper plate (131), and the nut (169) can be fastened to the protrusion of the fastening bolt (168). For example, when separating the top cover (130A) from the base structure (110A), the nut (169) can be separated from the fastening bolt (168), and the fastening bolt (168) can be removed from the base structure (110A) and the top cover (130A).

[0106]

[0107] (Example 9)

[0108] Fig. 13 is a perspective view showing an electric vehicle (500) according to exemplary embodiments of the present invention. Fig. 14 is a perspective view showing a portion of the electric vehicle (500) illustrated in Fig. 13.

[0109] Referring to FIGS. 13 and 14 together with FIG. 1, an electric vehicle (500) may include a vehicle frame (510) and a battery device (10). In FIGS. 13 and 14, for simplicity, only a portion of the electric vehicle (500) is illustrated.

[0110] The vehicle frame (510) may include a front frame (511) having front wheels (521) mounted thereon and a rear frame (513) having rear wheels (523) mounted thereon. The front frame (511) and the rear frame (513) may be spaced apart from each other with a battery device (10) therebetween.

[0111] The top cover (130) of the battery device (10) is coupled to the vehicle frame (510) and may form a chassis of the vehicle together with the vehicle frame (510). The battery device (10) may have a cell-to-chassis structure. The front frame (511) and the rear frame (513) may each be coupled to the top cover (130). The front frame (511) may be coupled to a front protrusion (1331) of an outer wall (133) of the top cover (130), and the rear frame (513) may be coupled to a rear protrusion (1332) of an outer wall (133) of the top cover (130).

[0112]

[0113] (Example 10)

[0114] FIG. 15 is a perspective view illustrating a method of separating a cell assembly (210) from an electric vehicle (500) according to exemplary embodiments of the present invention.

[0115] Referring to FIGS. 1 to 3, 13, and 15, the base structure (110) to which the cell assemblies (210) are attached is separated from the top cover (130) by removing the fastening bolts (161, 162). Thereafter, the defective cell assembly (210) can be separated from the base structure (110) through a process substantially the same as the method of separating the cell assembly (210) described with reference to FIGS. 7a and 7b and / or the method of separating the cell assembly (210) described with reference to FIGS. 9 and 10.

[0116]

[0117] 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. Base structure; A plurality of cell assemblies mounted on the base structure, each cell assembly including a plurality of battery cells; and A top cover comprising a pair of outer side walls coupled to the base structure and spaced apart from each other in a first direction and an upper plate covering the plurality of cell assemblies and having an upper cooling channel; A battery device comprising:

2. In paragraph 1, The top cover further includes a center wall disposed between the pair of outer walls and extending from the upper plate toward the base structure, A battery device characterized in that some of the plurality of cell assemblies are spaced apart in the first direction with the central wall interposed therebetween.

3. In paragraph 2, A battery device further comprising a plurality of fastening bolts for connecting the pair of outer walls and the center wall to the base structure.

4. In paragraph 1, A battery device characterized in that the base structure includes a lower cooling channel.

5. In paragraph 4, A lower inlet pipe coupled to the base structure and delivering a first cooling fluid provided from the outside to the inlet of the lower cooling channel; A lower outlet pipe coupled to the base structure and transmitting the first cooling fluid provided from the outlet of the lower cooling channel to the outside; An upper inlet pipe coupled to the upper plate and delivering a second cooling fluid provided from the outside to the inlet of the upper cooling channel; and An upper outlet pipe coupled to the upper plate and transmitting the second cooling fluid provided from the outlet of the upper cooling channel to the outside; A battery device characterized by further including:

6. In paragraph 1, further comprising a separation wall coupled to the base structure and extending in the first direction, A battery device characterized in that some of the plurality of cell assemblies are spaced apart in a second direction intersecting the first direction with the separating wall therebetween.

7. In paragraph 6, The above separation walls each include a lower separation wall and an upper separation wall mounted on the lower separation wall, The upper separating wall is attached to a corresponding cell assembly among the plurality of cell assemblies, A battery device characterized in that the lower separating wall is spaced apart from a corresponding cell assembly among the plurality of cell assemblies with the upper separating wall interposed therebetween.

8. In paragraph 1, A thermal resin layer attached to each of the plurality of cell assemblies; and A tape disposed between the thermal resin layer and the base structure; Including more, A battery device characterized in that the tape includes a portion protruding outward from the thermal resin layer.

9. In paragraph 8, A battery device characterized in that a portion of said tape is interposed between one of said pair of outer walls and said base structure.

10. In paragraph 8, A battery device characterized in that a surface of the base structure vertically overlapping one of the pair of outer walls is coplanar with a surface of the base structure vertically overlapping one of the plurality of cell assemblies.

11. In paragraph 8, The base structure includes an inclined surface extending in an inclined direction from a surface of the base structure vertically overlapping one of the pair of outer walls to a surface of the base structure vertically overlapping one of the plurality of cell assemblies, A battery device characterized in that the inclined surface of the base structure is in contact with the tape.

12. In paragraph 1, A battery device characterized in that each of the plurality of cell assemblies is attached to the upper plate through a thermally conductive adhesive layer.

13. In paragraph 1, heat dissipation fins connected to the plurality of cell assemblies; and A thermally conductive adhesive layer that attaches the heat dissipation fin to the upper plate; A battery device characterized by further comprising:

14. In paragraph 1, The base structure includes a bottom plate supporting the plurality of cell assemblies and a center wall extending from the bottom plate toward the upper plate of the top cover, Some of the above plurality of cell assemblies are spaced apart in the first direction with the center wall therebetween, A battery device further comprising a fastening bolt for fastening the center wall of the base structure to the upper plate of the top cover, wherein the fastening bolt penetrates the bottom plate, the center wall, and the upper plate.

15. Vehicle frame; and A battery device connected to the vehicle frame; Including, The above battery device, Base structure with lower cooling channels; A plurality of cell assemblies mounted on the base structure, each cell assembly including a plurality of battery cells; and A top cover comprising a pair of outer side walls coupled to the base structure and spaced apart in a first direction and an upper plate covering the plurality of cell assemblies and having an upper cooling channel; Including, An electric vehicle, wherein the above vehicle frame is coupled to the above top cover.

16. In paragraph 15, The above vehicle frame, Front frame with front wheel; and A rear frame having rear wheels and spaced apart from the front frame; Including, The pair of outer side walls of the top cover include a front protrusion protruding forward from the base structure and a rear protrusion protruding rearward from the base structure, The above front frame is joined to the above front protrusions of the pair of outer walls, An electric vehicle characterized in that the rear frame is connected to the rear protrusions of the pair of outer side walls.

17. In paragraph 15, The top cover further includes a center wall disposed between the pair of outer walls and extending from the upper plate toward the base structure, An electric vehicle, characterized in that some of the plurality of cell assemblies are spaced apart in the first direction with the central wall interposed therebetween.

18. In paragraph 17, A plurality of fastening bolts for connecting the pair of outer walls and the center wall to the base structure; A thermal resin layer attached to each of the plurality of cell assemblies; and A tape disposed between the thermal resin layer and the base structure; An electric vehicle characterized by further including:

19. In paragraph 17, An electric vehicle characterized in that the top cover is a single integrated structure including the pair of outer walls, the upper plate, and the center wall.

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