Battery pack

Abstract

The technical concept of the present invention is to provide a battery pack comprising a pack housing and a cell assembly disposed within the pack housing, the cell assembly comprising: a plurality of battery cells; and a heat transfer structure comprising a top plate disposed on the plurality of battery cells, and a plurality of side plates in contact with the plurality of battery cells, wherein each of the plurality of side plates is fitted to the top plate.

Description

battery pack

[0001] The present invention relates to a battery pack.

[0002] This application claims the benefit of priority from Republic of Korea Patent Application No. 10-2024-0088217, filed July 4, 2024, and all contents of the document in that Republic of Korea Patent Application 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 pack.

[0006] In order to solve the above-described problem, the technical idea of ​​the present invention provides a battery pack including: a pack housing; and a cell assembly disposed within the pack housing; wherein the cell assembly includes: a plurality of battery cells; and a heat transfer structure including a top plate on the plurality of battery cells and a plurality of side plates in contact with the plurality of battery cells; wherein the plurality of side plates are each fittedly connected to the top plate.

[0007] In exemplary embodiments, the top plate includes a plurality of insertion holes, and the plurality of side plates are each characterized by including a protrusion inserted into a corresponding insertion hole among the plurality of insertion holes of the top plate.

[0008] In exemplary embodiments, the top plate comprises a plurality of unit plates separated from each other, each of the plurality of unit plates being coupled to a corresponding at least one side plate among the plurality of side plates.

[0009] In exemplary embodiments, the plurality of battery cells are arranged in a first direction, the plurality of side plates are spaced apart from each other in the first direction, and the plurality of unit plates of the top plate are arranged in the first direction.

[0010] In exemplary embodiments, the pack housing comprises a base frame supporting the cell assembly, the base frame being characterized in that it is attached to the plurality of battery cells by a first thermally conductive adhesive layer.

[0011] In exemplary embodiments, the base frame is characterized by including a first cooling channel through which a cooling fluid flows.

[0012] In exemplary embodiments, the pack housing further comprises an upper cooling structure disposed on the cell assembly, the upper cooling structure being characterized in that it is attached to the top plate of the heat transfer structure by a second thermally conductive adhesive layer.

[0013] In exemplary embodiments, the upper cooling structure is characterized by including a second cooling channel through which a cooling fluid flows.

[0014] In exemplary embodiments, the heat transfer structure further includes a plurality of cell accommodation spaces separated from each other in a first direction and each extending in a second direction perpendicular to the first direction; and a plurality of venting channels separated from each other in the first direction and each extending in the second direction; wherein each of the plurality of cell accommodation spaces accommodates a corresponding battery cell among the plurality of battery cells, and wherein each of the plurality of venting channels is on a corresponding cell accommodation space among the plurality of cell accommodation spaces and is configured to guide a gas in the second direction.

[0015] In exemplary embodiments, the plurality of venting channels each extend in the second direction from a first end to a second end, the cell assembly includes a blocking plate closing the first end of each of the plurality of venting channels, and in each of the plurality of venting channels, gas flows in a direction from the first end of each of the plurality of venting channels toward the second end of each of the plurality of venting channels.

[0016] In exemplary embodiments, the blocking plate is characterized in that it is a part of the top plate of the heat transfer structure.

[0017] In exemplary embodiments, the pack housing comprises first and second sidewalls spaced apart in the second direction; and third and fourth sidewalls spaced apart in the first direction; wherein the second end of each of the plurality of venting channels faces the first sidewall, and wherein the third sidewall of the pack housing is equipped with a venting device.

[0018] In exemplary embodiments, the plurality of battery cells are arranged in a first direction, the pack housing further includes a base frame supporting the cell assembly and a support structure extending in a second direction perpendicular to the first direction on the base frame, and the cell assembly further includes a fastening frame attached to a battery cell that is outermost in the first direction among the plurality of battery cells and fastened to the support structure.

[0019] According to exemplary embodiments of the present invention, the battery pack has a dual cooling structure that cools the battery cells through a base frame provided on the lower side of the cell assembly and an upper cooling structure provided on the upper side of the cell assembly, thereby improving the cooling performance for the battery cells.

[0020] According to exemplary embodiments of the present invention, a heat transfer structure configured to thermally couple battery cells to an upper cooling structure can be manufactured relatively easily through a fitting joint between a top plate and a side plate, thereby reducing the difficulty of manufacturing the heat transfer structure.

[0021] According to exemplary embodiments of the present invention, high-temperature gas generated from a plurality of battery cells is discharged along a venting direction provided by a heat transfer structure, thereby implementing directional venting that discharges venting gas in a predetermined specific direction.

[0022] 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.

[0023] FIG. 1 is a perspective view showing a cell assembly according to exemplary embodiments of the present invention.

[0024] FIG. 2 is a cross-sectional view illustrating a battery pack including a cell assembly according to exemplary embodiments of the present invention.

[0025] FIG. 3 is a cross-sectional view showing a heat transfer structure and a fastening frame of a cell assembly according to exemplary embodiments of the present invention.

[0026] FIG. 4 is a perspective view showing an assembly process of a unit structure of a heat transfer structure according to exemplary embodiments of the present invention.

[0027] FIG. 5 is a perspective view showing a unit structure of a heat transfer structure according to exemplary embodiments of the present invention.

[0028] FIG. 6 is a cross-sectional view illustrating a battery pack including a cell assembly according to exemplary embodiments of the present invention.

[0029] FIG. 7 is a perspective view showing a unit structure of a heat transfer structure according to exemplary embodiments of the present invention.

[0030] FIG. 8 is a perspective view illustrating a battery pack according to exemplary embodiments of the present invention.

[0031] FIG. 9 is a perspective view showing a portion of a battery pack according to exemplary embodiments of the present invention.

[0032] Fig. 10 is a cross-sectional view of a battery pack taken along line CC-CC' of Fig. 8.

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

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

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

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

[0037]

[0038] (Example 1)

[0039] FIG. 1 is a perspective view illustrating a cell assembly (100) according to exemplary embodiments of the present invention. FIG. 2 is a cross-sectional view illustrating a battery pack (500) including a cell assembly (100) according to exemplary embodiments of the present invention. In FIG. 2, a cross-section of the cell assembly (100) taken along the line AA-AA' of FIG. 1 is illustrated. FIG. 3 is a cross-sectional view illustrating a heat transfer structure (110) and a fastening frame (160) of the cell assembly (100) according to exemplary embodiments of the present invention. In FIG. 3, a cross-section of the heat transfer structure (110) and a cross-section of the fastening frame (160) taken along the line AA-AA' of FIG. 1 are illustrated. FIG. 4 is a perspective view illustrating an assembly process of a unit structure (119) of a heat transfer structure (110) according to exemplary embodiments of the present invention.

[0040] Referring to FIGS. 1 to 4, a cell assembly (100) may include a heat transfer structure (110), a plurality of battery cells (130), and a fastening frame (160).

[0041] A heat transfer structure (110) may be connected to a plurality of battery cells (130) and configured to transfer heat of the plurality of battery cells (130) to a cooling structure such as a heat sink. The heat transfer structure (110) may include a plurality of side plates (111) spaced apart from each other in a first horizontal direction (e.g., X-direction), and a top plate (113) disposed on the plurality of side plates (111). Each of the side plates (111) may have a flat plate shape extending in a second horizontal direction (e.g., Y-direction) and a vertical direction (e.g., Z-direction). The top plate (113) may be connected to the top of each of the plurality of side plates (111). The top plate (113) may have a flat plate shape extending in a first horizontal direction (e.g., X-direction) and a second horizontal direction (e.g., Y-direction).

[0042] The heat transfer structure (110) may include a material having excellent thermal conductivity. For example, the heat transfer structure (110) may include aluminum, copper, silver, gold, iron, tungsten, or a combination thereof.

[0043] The heat transfer structure (110) can provide a plurality of cell accommodation spaces (121) that are separated from each other. Each of the plurality of cell accommodation spaces (121) can accommodate one or more battery cells (130). The plurality of cell accommodation spaces (121) can be separated from each other in a first horizontal direction (e.g., X direction), and each of the plurality of cell accommodation spaces (121) can extend in a second horizontal direction (e.g., Y direction). Adjacent cell accommodation spaces (121) among the plurality of cell accommodation spaces (121) can be separated by corresponding side plates (111) among the plurality of side plates (111).

[0044] The heat transfer structure (110) can provide a plurality of venting channels (125) that are separated from each other. The plurality of venting channels (125) can be separated from each other in a first horizontal direction (e.g., X direction). Adjacent venting channels (125) among the plurality of venting channels (125) can be separated by corresponding side plates (111) among the plurality of side plates (111). Each venting channel (125) can extend in a second horizontal direction (e.g., Y direction). Each venting channel (125) can be provided on an upper side of a corresponding cell accommodation space (121) among the plurality of cell accommodation spaces (121) and can be in communication with the corresponding cell accommodation space (121). Each venting channel (125) may be defined by the upper surfaces of two adjacent side plates (111), a top plate (113), and one or more battery cells (130) accommodated in the corresponding cell accommodation space (121). That is, each venting channel (125) may be provided between the top plate (113) and one or more battery cells (130) accommodated in the cell accommodation space (121) in a vertical direction (e.g., Z direction), and may be provided between two adjacent side plates (111) in a first horizontal direction (e.g., X direction).

[0045] Each venting channel (125) may be configured to guide or transmit high-temperature gas generated from one or more battery cells (130) accommodated in a corresponding cell accommodation space (121) in a second horizontal direction (e.g., Y direction). The top plate (113) may cover the plurality of venting channels (125) and the plurality of battery cells (130) so as to block the gas from flowing in a vertical direction (e.g., Z direction) between the individual venting channels (125) and the space above the cell assembly (100). In the individual venting channels (125), the high-temperature gas may flow in a second horizontal direction (e.g., Y direction) along the lower surface of the top plate (113) facing the plurality of battery cells (130). Each venting channel (125) may extend in a second horizontal direction (e.g., Y direction) and may have a first end (1251 of FIG. 6) and a second end (1253 of FIG. 6) opposite to each other in the second horizontal direction (e.g., Y direction). At least one of the first end (1251) and the second end (1253) of each venting channel (125) may be exposed to an external space outside the cell assembly (100), such that gas flow between the external space of the cell assembly (100) and each venting channel (125) may be permitted.

[0046] A plurality of side plates (111) may be respectively fitted into a top plate (113). In exemplary embodiments, the plurality of side plates (111) may each include a protrusion (1111) provided on an upper portion thereof, and the top plate (113) may include a plurality of insertion holes (1131). The individual side plates (111) may be coupled to the top plate (113) by the protrusions (1111) of the individual side plates (111) being inserted into corresponding insertion holes (1131) of the top plate (113). For example, the insertion holes (1131) of the top plate (113) may have a slit shape extending in a second horizontal direction (e.g., the Y direction), and the protrusions (1111) of the individual side plates (111) may extend along the insertion holes (1131) of the top plate (113) in the second horizontal direction (e.g., the Y direction).

[0047] In exemplary embodiments, the top plate (113) may include a plurality of unit plates (115). The plurality of unit plates (115) may be arranged in a first horizontal direction (e.g., X-direction), and adjacent unit plates (115) may be in contact with each other. When viewed in a plan view, the plurality of unit plates (115) may each have a rectangular shape, and the top plate (113), which is an assembly of the plurality of unit plates (115), may have a rectangular shape. The plurality of unit plates (115) of the top plate (113) may each include an insertion hole (1131) and may be fit-coupled to at least one side plate (111).

[0048] The heat transfer structure (110) may include a plurality of unit structures (119). The plurality of unit structures (119) may be arranged in a first horizontal direction (e.g., X-direction), and the heat transfer structure (110) may be understood as an aggregate of the plurality of unit structures (119). Each unit structure (119) may include a single unit plate (115) and at least one side plate (111) coupled to the single unit plate (115). In exemplary embodiments, each unit structure (119) may include a single unit plate (115) and a single side plate (111), and may have a T-shaped cross-section. To manufacture each unit structure (119), a step of manufacturing each of the unit plate (115) and the side plate (111) and a step of assembling the unit plate (115) and the side plate (111) may be sequentially performed. The unit plate (115) and the side plate (111) can each be manufactured by a pressing process using a press mold. The assembly between the unit plate (115) and the side plate (111) can include fitting the protrusion (1111) of the side plate (111) into the insertion hole (1131) of the unit plate (115).

[0049] A plurality of battery cells (130) can be accommodated in a plurality of cell accommodation spaces (121) of a heat transfer structure (110) and can be arranged in a first horizontal direction (e.g., X direction). The battery cells (130) accommodated in different cell accommodation spaces (121) of the heat transfer structure (110) can be separated by side plates (111). Each battery cell (130) can be attached to a corresponding side plate (111) among the plurality of side plates (111) by an adhesive member. The adhesive member can include, for example, an adhesive tape or a resin layer.

[0050] In exemplary embodiments, at least one of the plurality of cell receiving spaces (121) of the heat transfer structure (110) can receive one or more battery cells (130), for example, two battery cells (130), arranged in a first horizontal direction (e.g., X-direction).

[0051] In exemplary embodiments, at least one of the plurality of cell receiving spaces (121) of the heat transfer structure (110) may include a pad (140) and two battery cells (130) spaced apart from each other with the pad (140) therebetween. The pad (140) may be attached to each of the two battery cells (130) by an adhesive member made of an adhesive tape or a resin layer. The pad (140) may correspond to a thermal barrier pad configured to thermally isolate the two battery cells (130) and support the two battery cells (130) in a first horizontal direction (e.g., the X-direction). For example, the pad (140) may include polyurethane, silicone, or a combination thereof.

[0052] The battery cell (130) is accommodated in the cell accommodation space (121) of the heat transfer structure (110) and may extend in a second horizontal direction (e.g., Y direction) within the cell accommodation space (121). An electrode lead (131 of FIG. 6) may be provided at at least one of both ends of the battery cell (130) along the second horizontal direction (e.g., Y direction). When the battery cell (130) is accommodated in the cell accommodation space (121) of the heat transfer structure (110), two side surfaces of the battery cell (130) may be covered by two side plates (111) adjacent in the first horizontal direction (e.g., X direction), and the upper surface of the battery cell (130) may be covered by the top plate (113). In exemplary embodiments, the bottom surface of the battery cell (130) may be exposed to the outside of the heat transfer structure (110) without being covered by the heat transfer structure (110).

[0053] An individual battery cell (130) is a basic unit of a lithium ion battery, i.e., a secondary battery. An individual battery cell (130) may include an electrode assembly, an electrolyte, and a cell case. The electrode assembly built into the cell case may include a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode. The electrode assembly may be either a jelly-roll type or a stack type depending on the assembly form. A jelly-roll type electrode assembly may include a winding structure of a positive electrode, a negative electrode, and a separator interposed therebetween. A stack type electrode assembly may include a plurality of sequentially stacked positive electrodes, a plurality of negative electrodes, and a plurality of separators interposed therebetween. The positive electrode may include a positive electrode current collector and a positive electrode active material. The negative electrode may include a negative electrode current collector and an negative electrode active material.

[0054] A plurality of battery cells (130) may be connected in series and / or in parallel. For example, a plurality of battery cells (130) may be connected in series with each other. For example, a plurality of battery cells (130) may also be connected in parallel with each other. For example, when a set of two or more battery cells (130) connected in parallel with each other is defined as a bank, one bank composed of two or more battery cells (130) connected in parallel with each other and another bank composed of two or more battery cells (130) connected in parallel with each other may be connected in series.

[0055] An individual battery cell (130) may correspond to a pouch-type battery cell, a cylindrical battery cell, or a square battery cell. The electrode assembly of a pouch-type battery cell is housed in a pouch case including an aluminum laminate sheet. The electrode assembly of a cylindrical battery cell is housed in a cylindrical metal can. The electrode assembly of a square battery cell is housed in a square metal can. In exemplary embodiments, an individual battery cell (130) corresponds to a pouch-type battery cell, and a length of an individual battery cell (130) along a second horizontal direction (e.g., Y direction) may be greater than a length of an individual battery cell (130) along a first horizontal direction (e.g., X direction) and a length of an individual battery cell (130) along a vertical direction (e.g., Z direction).

[0056] A plurality of battery cells (130) may be arranged in a first horizontal direction (e.g., X direction) to form a cell block. When viewed in a plan view, the cell block may have a rectangular shape. The cell block may have two opposite sides (i.e., a first side and a second side) in the first horizontal direction (e.g., X direction), a front side and a back side opposite in the second horizontal direction (e.g., Y direction), and a top side and a bottom side opposite in the vertical direction (e.g., Z direction).

[0057] A busbar frame (171) supporting electrode leads (131) of a plurality of battery cells (130) may be arranged on each of the front and rear sides of the cell block. The busbar frame (171) on the front side of the cell block may be provided with slits into which the electrode leads (131) are inserted, and the busbar frame (171) on the rear side of the cell block may be provided with slits into which the electrode leads (131) are inserted.

[0058] The busbar frame (171) can support busbars (173). The busbars (173) can be electrically and physically connected to at least one of the electrode leads (131) of the plurality of battery cells (130). The busbar (173) can be joined to at least one of the electrode leads (131) of the plurality of battery cells (130) by welding. The busbar (173) can include a terminal busbar for electrically connecting a cell block of the cell assembly (100) to a cell block of another cell assembly or to an external device. In exemplary embodiments, the busbars (173) can include an inter-busbar for electrically connecting different battery cells (130) by connecting to the electrode leads (131) of different battery cells (130).

[0059] The cell assembly (100) may further include insulating covers (175) connected to the busbar frames (171). One insulating cover (175) may cover the busbar frame (171) at the front of the cell block and cover the electrode leads (131) and busbars (173) supported by the busbar frame (171) at the front of the cell block. Another insulating cover (175) may cover the busbar frame (171) at the rear of the cell block and cover the electrode leads (131) and busbars (173) supported by the busbar frame (171) at the rear of the cell block.

[0060] The fastening frame (160) may be attached to each of the battery cells (130) that are outermost in the first horizontal direction (e.g., X direction) among the plurality of battery cells (130). The fastening frame (160) may be fastened to an external support structure (530). For example, the support structure (530) may be provided to a pack housing (see 501 of FIG. 8) of a battery pack (500) on which a cell assembly (100) is mounted, and the cell assembly (100) may be mounted to the pack housing (501) through a connection between the fastening frame (160) and the support structure (530).

[0061] The fastening frame (160) can cover one side of the battery cell (130) and can be attached to one side of the battery cell (130) by an adhesive member composed of an adhesive tape or a resin layer. The fastening frame (160) can be fastened to an external support structure (530) by a bolt (551). For example, the fastening frame (160) can include a fixing plate (161) attached to the battery cell (130) and a flange (163) fastened to the external support structure (530) by a bolt (551). The flange (163) can be connected to the upper portion of the fixing plate (161) and can be seated on the external support structure (530).

[0062] A battery pack (500) may include a cell assembly (100), a base frame (510) supporting the cell assembly (100), and an upper cooling structure (560) on the cell assembly (100). The base frame (510) and the upper cooling structure (560) may be part of a pack housing (501).

[0063] A base frame (510) may be provided below the cell assembly (100) and may support a plurality of battery cells (130). A first thermally conductive adhesive layer (191) may be disposed between each of the plurality of battery cells (130) and the base frame (510). The first thermally conductive adhesive layer (191) may attach each of the plurality of battery cells (130) to the base frame (510). An upper portion of the first thermally conductive adhesive layer (191) may be in direct contact with each of the plurality of battery cells (130), and a lower portion of the first thermally conductive adhesive layer (191) may be in direct contact with the base frame (510). The first thermally conductive adhesive layer (191) may thermally and physically couple each of the plurality of battery cells (130) to the base frame (510). The first thermally conductive adhesive layer (191) may include a thermal resin and / or a thermal interface material (TIM).

[0064] The base frame (510) may include a first cooling channel (511) configured to allow a cooling fluid to flow therethrough. The first cooling channel (511) of the base frame (510) may extend in a first horizontal direction (e.g., an X-direction) within the base frame (510). A cooling fluid provided from the outside of the base frame (510) may be supplied to an inlet of the first cooling channel (511), flow along the first cooling channel (511), and discharged to the outside through an outlet of the first cooling channel (511). While the cooling fluid flows along the first cooling channel (511), cooling of the cell assembly (100) may be performed. The cooling fluid may include a coolant and / or a refrigerant. In the present disclosure, the base frame (510) may be referred to as a lower cooling structure.

[0065] The upper cooling structure (560) may be disposed on the top plate (113) of the heat transfer structure (110), and a second thermally conductive adhesive layer (193) may be disposed between the upper cooling structure (560) and the top plate (113) of the heat transfer structure (110). The second thermally conductive adhesive layer (193) may attach the upper cooling structure (560) to the top plate (113) of the heat transfer structure (110). An upper portion of the second thermally conductive adhesive layer (193) may be in direct contact with the upper cooling structure (560), and a lower portion of the second thermally conductive adhesive layer (193) may be in direct contact with the top plate (113) of the heat transfer structure (110). The second thermally conductive adhesive layer (193) can thermally and physically couple the upper cooling structure (560) to the heat transfer structure (110). Since the plurality of battery cells (130) are thermally coupled to the upper cooling structure (560) by the heat transfer structure (110) and the second thermally conductive adhesive layer (193), heat generated from the plurality of battery cells (130) can be transferred to the upper cooling structure (560) through the heat transfer structure (110) and the second thermally conductive adhesive layer (193). The second thermally conductive adhesive layer (193) can include a thermal resin and / or a TIM. Since the second thermally conductive adhesive layer (193) is placed on the top plate (113) of the thermal transfer structure (110), a plurality of battery cells (130) can be separated from the second thermally conductive adhesive layer (193) by the thermal transfer structure (110).

[0066] The upper cooling structure (560) may include a second cooling channel (561) configured to allow a cooling fluid to flow therethrough. The second cooling channel (561) of the upper cooling structure (560) may extend in a first horizontal direction (e.g., an X-direction) within the upper cooling structure (560). A cooling fluid provided from the outside of the upper cooling structure (560) may be supplied to an inlet of the second cooling channel (561), flow along the second cooling channel (561), and be discharged to the outside through an outlet of the second cooling channel (561). While the cooling fluid flows along the second cooling channel (561), cooling of the cell assembly (100) may be achieved. The cooling fluid may include a cooling water and / or a refrigerant.

[0067] According to exemplary embodiments of the present invention, the battery pack (500) has a dual cooling structure that cools the battery cells (130) through a base frame (510) provided on the lower side of the cell assembly (100) and an upper cooling structure (560) provided on the upper side of the cell assembly (100), thereby improving the cooling performance for the battery cells (130).

[0068] According to exemplary embodiments of the present invention, a heat transfer structure (110) configured to thermally couple battery cells (130) to an upper cooling structure (560) can be easily manufactured through a fitting connection between a top plate (113) and a side plate (111), thereby reducing the difficulty of manufacturing the heat transfer structure (110).

[0069] According to exemplary embodiments of the present invention, when disassembling a battery pack (500) for a rework operation, the battery cells (130) are protected by being covered by a heat transfer structure (110) without being in direct contact with an adhesive such as TIM or thermal resin, thereby preventing the battery cells (130) from being damaged during the rework operation.

[0070] According to exemplary embodiments of the present invention, the cell assembly (100) may have a cell-to-pack structure that is directly assembled into the pack housing (501) of the battery pack (500). The battery cells (130) of the cell assembly (100) may be thermally coupled to cooling structures that cool the battery cells (130) without being covered by a structure such as a module frame, thereby improving cooling efficiency for the plurality of battery cells (130). In addition, the cell assembly (100) has a fastening frame (160) configured to be fastened to the pack housing (501) of the battery pack (500), thereby eliminating an assembly gap between the cell assembly (100) and the pack housing (501), thereby improving the energy density of the battery pack (500).

[0071]

[0072] (Example 2)

[0073] FIG. 5 is a perspective view showing a unit structure (119A) of a heat transfer structure (110) according to exemplary embodiments of the present invention.

[0074] Referring to FIG. 5 together with FIG. 3, in the heat transfer structure (110), each unit structure (119A) may include a single unit plate (115A) and a plurality of side plates (111) coupled to the single unit plate (115A). In FIG. 5, five side plates (111) are coupled to the single unit plate (115A), but this is not limited thereto, and the number of side plates (111) coupled to the single unit plate (115A) may be two or more. In the heat transfer structure (110), the stiffness of each unit structure (119A) may be adjusted by adjusting the number of side plates (111) coupled to the single unit plate (115A).

[0075] In some exemplary embodiments, the top plate (113) of the heat transfer structure (110) may be a single plate, and all side plates (111) of the heat transfer structure (110) may be joined to the single plate.

[0076]

[0077] (Example 3)

[0078] Fig. 6 is a cross-sectional view illustrating a battery pack (500A) including a cell assembly (100A) according to exemplary embodiments of the present invention. In Fig. 6, a cross-section of the cell assembly (100A) taken along a line corresponding to the line BB-BB' of Fig. 1 is illustrated. Fig. 7 is a perspective view illustrating a unit structure (119B) of a heat transfer structure (110A) according to exemplary embodiments of the present invention.

[0079] Referring to FIGS. 6 and 7, the cell assembly (100A) may include a blocking plate (150) connected to an end of the heat transfer structure (110A) along a second horizontal direction (e.g., Y direction). The blocking plate (150) may close one end of each of the plurality of venting channels (125) of the heat transfer structure (110A) so that gas is discharged in only one direction within the plurality of venting channels (125). For example, the blocking plate (150) may extend in the first horizontal direction (e.g., X direction) to close one end of each of the plurality of venting channels (125).

[0080] The blocking plate (150) can close the first end (1251) of the individual venting channel (125) provided in the heat transfer structure (110A) so as not to allow the flow of gas through the first end (1251) of the individual venting channel (125). Since the first end (1251) of the individual venting channel (125) is closed by the blocking plate (150), the gas within the individual venting channel (125) can flow in one venting direction (VD1) from the first end (1251) of the individual venting channel (125) toward the second end (1253) and be discharged to the outside of the cell assembly (100A) through the second end (1253) of the individual venting channel (125). The second end (1253) of each venting channel (125) may be an outlet of the venting channel (125) through which gas is discharged to the outside. When gas is generated in the battery cell (130), the gas generated in the battery cell (130) may flow in one venting direction (VD1) along the venting channel (125) located on the upper side of the battery cell (130), and may then be discharged to the outside of the cell assembly (100A) through the second end (1253) of the venting channel (125).

[0081] In exemplary embodiments, the blocking plate (150) may be a portion of a top plate (113A) of a heat transfer structure (110A). The top plate (113A) may include a main plate to which a plurality of side plates (111) are coupled, and a blocking plate (150) extending along one edge of the main plate. For example, a top plate (113A) having a main plate and a blocking plate (150) may be manufactured by bending a flat member. In exemplary embodiments, the top plate (113A) may be an assembly of a plurality of unit plates (115B), and each unit plate (115B) may include a unit blocking plate (151). The blocking plate (150) may be an assembly of a plurality of unit blocking plates (151) of a plurality of unit plates (115B) connected in a first horizontal direction (e.g., an X-direction).

[0082] According to exemplary embodiments of the present invention, high-temperature gas generated from a plurality of battery cells (130) is discharged along a venting direction (VD1) provided by a heat transfer structure (110A), so that directional venting that discharges the venting gas in a predetermined specific direction can be implemented.

[0083]

[0084] (Example 4)

[0085] Fig. 8 is a perspective view illustrating a battery pack (500B) according to exemplary embodiments of the present invention. Fig. 9 is a perspective view illustrating a portion of a battery pack (500B) according to exemplary embodiments of the present invention. Fig. 10 is a cross-sectional view of the battery pack (500B) taken along line CC-CC' of Fig. 8.

[0086] Referring to FIGS. 8 to 10 together with FIGS. 6 and 7, a battery pack (500B) may include a pack housing (501) and a plurality of cell assemblies (100A) mounted within the pack housing (501). In exemplary embodiments, the battery pack (500B) may include a plurality of cell assemblies (100A) arranged in a first horizontal direction (e.g., X-direction) and a second horizontal direction (e.g., Y-direction).

[0087] The pack housing (501) may provide a receiving space in which the cell assemblies (100A) are received. The pack housing (501) may include a base frame (510), a side frame (520), and an upper cooling structure (560). The side frame (520) may be coupled to an edge of the base frame (510) and may extend along a perimeter of the side frame (520) to surround a plurality of cell assemblies (100A). The side frame (520) may be coupled to an edge of the base frame (510) and may extend along a perimeter of the base frame (510) to surround a plurality of cell assemblies (100A). The upper cooling structure (560) may be coupled on the side frame (520) to cover the receiving space of the pack housing (501). The receiving space of the pack housing (501) may be a closed space.

[0088] The base frame (510) may have a flat plate shape parallel to a first horizontal direction (e.g., X-direction) and a second horizontal direction (e.g., Y-direction). The base frame (510) may support a cell assembly (100A). The cell assembly (100A) may be thermally coupled to the base frame (510) via a first thermally conductive adhesive layer (191) interposed between the cell assembly (100A) and the base frame (510). In exemplary embodiments, the bottom surfaces of the plurality of battery cells (130) are not covered by the thermally conductive structure (110A) so as to be exposed to the outside of the thermally conductive structure (110A), and the bottom surfaces of the plurality of battery cells (130) may be connected to the base frame (510) via the first thermally conductive adhesive layer (191).

[0089] An upper cooling structure (560) may be disposed on a plurality of cell assemblies (100A). The upper cooling structure (560) may have a flat plate shape parallel to a first horizontal direction (e.g., X-direction) and a second horizontal direction (e.g., Y-direction). Individual cell assemblies (100A) may be coupled to the upper cooling structure (560) via a second thermally conductive adhesive layer (193) interposed between the heat transfer structure (110A) and the upper cooling structure (560). The battery cells (130) of the individual cell assemblies (100A) may be thermally coupled to the upper cooling structure (560) via the thermally conductive structure and the second thermally conductive adhesive layer (193). In exemplary embodiments, the upper cooling structure (560) may be a pack lid connected on a side frame (520) to cover an accommodation space of the pack housing (501). In other exemplary embodiments, the pack housing (501) may include a pack lid separate from the upper cooling structure (560), and the upper cooling structure (560) may be positioned between the pack lid and the cell assembly (100A).

[0090] The side frame (520) may include a first side wall (521) and a second side wall (523) facing and spaced apart in a second horizontal direction (e.g., Y direction), and a third side wall (525) and a fourth side wall (527) facing and spaced apart in a first horizontal direction (e.g., X direction). The side walls of the pack housing (501) may surround an accommodation space. The third side wall (525) of the pack housing (501) may be a front wall forming a front portion of the battery pack (500B), and the fourth side wall (527) of the pack housing (501) may be a rear wall forming a rear portion of the battery pack (500B).

[0091] A venting device (540) may be mounted on the third side wall (525) of the pack housing (501). The venting device (540) may be mounted in an exhaust passage provided between the receiving space of the pack housing (501) and the external space of the pack housing (501), and may be configured to selectively exhaust gas between the receiving space of the pack housing (501) and the external space of the pack housing (501). In exemplary embodiments, the venting device (540) may include a check valve, a relief valve, a safety valve, and / or a rupture disc.

[0092] In exemplary embodiments, the venting device (540) may be a relief valve configured to selectively open and close a gas exhaust passage depending on the internal pressure of the receiving space of the pack housing (501). The relief valve may be configured to open the gas exhaust passage to discharge gas to the outside of the pack housing (501) when the internal pressure of the receiving space of the pack housing (501) becomes higher than a reference pressure, and to close the gas exhaust passage when the gas is discharged and the internal pressure of the receiving space of the pack housing (501) becomes lower than the reference pressure.

[0093] The pack housing (501) may include a plurality of support structures (530) provided on a base frame (510). The plurality of support structures (530) may be provided on an upper surface of the base frame (510) and may be spaced apart from each other in a first horizontal direction (e.g., X-direction). The plurality of support structures (530) may each extend in a second horizontal direction (e.g., Y-direction). The plurality of support structures (530) may each be referred to as a cross beam structure. The plurality of support structures (530) may separate or partition an accommodation space of the pack housing (501) into a plurality of sub-accommodation spaces. The plurality of sub-accommodation spaces are separated or partitioned in a first horizontal direction (e.g., X-direction), and one cell assembly (100A) may be arranged in each sub-accommodation space.

[0094] The fastening frame (160) of each cell assembly (100A) can be placed on a corresponding support structure (530) among the plurality of support structures (530). The individual cell assembly (100A) can be fastened to the pack housing (501) by fastening the fastening frame (160) to a corresponding support structure (530) among the plurality of support structures (530) by bolts (551). More specifically, the individual cell assembly (100A) can be fastened to the pack housing (501) by fastening a pair of fastening frames (160) to a corresponding pair of support structures (530) among the plurality of battery support structures (530).

[0095] In exemplary embodiments, two adjacent cell assemblies (100A) in a first horizontal direction (e.g., X-direction) may share the same single support structure (530). That is, the single support structure (530) may be fastened to a fastening frame (160) of one of the two adjacent cell assemblies (100A) and to a fastening frame (160) of the other of the two adjacent cell assemblies (100A).

[0096] In exemplary embodiments, an individual cell assembly (100A) may be configured to discharge gas in a venting direction (VD1), and an outlet of the individual cell assembly (100A) in the venting direction (VD1) may face one of the first sidewall (521) and the second sidewall (523). An individual cell assembly (100A) may be mounted in a pack housing (501) such that a second end (1253) of a venting channel (125) having an outlet of the venting channel (125) directly faces one of the first sidewall (521) and the second sidewall (523). In this case, the gas discharged from each cell assembly (100A) can flow along the venting direction (VD2) parallel to the first horizontal direction (e.g., X direction) along the first side wall (521) or the second side wall (523) to reach the third side wall (525), and the gas guided to the third side wall (525) can be discharged to the outside of the battery pack (500B) through the venting device (540) provided in the third side wall (525).

[0097] In exemplary embodiments, the battery pack (500B) may include a plurality of cell assemblies (100A) arranged in two rows. The cell assemblies (100A) in the first row may be arranged in a first horizontal direction (e.g., X-direction) and closer to the first sidewall (521) than to the second sidewall (523). The cell assemblies (100A) in the second row may be arranged in the first horizontal direction (e.g., X-direction) and closer to the second sidewall (523) than to the first sidewall (521). In this case, the cell assemblies (100A) in the first row may be arranged such that each outlet in one venting direction (VD1) faces the first sidewall (521), and the cell assemblies (100A) in the second row may be arranged such that each outlet in one venting direction (VD1) faces the second sidewall (523). The gas discharged from the cell assemblies (100A) of the first row can flow along the venting direction (VD2) parallel to the first horizontal direction (e.g., X direction) along the first side wall (521) to reach the third side wall (525), and the gas guided to the third side wall (525) can be discharged to the outside of the battery pack (500B) through the venting device (540) provided in the third side wall (525). Additionally, the gas discharged from the cell assemblies (100A) of the second row can flow along the venting direction (VD2) parallel to the first horizontal direction (e.g., X direction) along the second side wall (523) to reach the third side wall (525), and the gas guided to the third side wall (525) can be discharged to the outside of the battery pack (500B) through the venting device (540) provided in the third side wall (525).

[0098] 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. Pack housing; and A cell assembly disposed within the pack housing; Including, The above cell assembly, multiple battery cells; and A heat transfer structure including a top plate on the plurality of battery cells and a plurality of side plates in contact with the plurality of battery cells; Including, A battery pack, wherein each of the plurality of side plates is fitted and connected to the top plate.

2. In paragraph 1, The top plate includes a plurality of insertion holes, A battery pack characterized in that each of the plurality of side plates includes a protrusion inserted into a corresponding insertion hole among the plurality of insertion holes of the top plate.

3. In paragraph 1, The top plate comprises a plurality of unit plates separated from each other, A battery pack, characterized in that each of the plurality of unit plates is coupled to at least one corresponding side plate among the plurality of side plates.

4. In paragraph 3, The above plurality of battery cells are arranged in a first direction, The above plurality of side plates are spaced apart from each other in the first direction, A battery pack characterized in that the plurality of unit plates of the top plate are arranged in the first direction.

5. In paragraph 1, The above pack housing includes a base frame supporting the cell assembly, A battery pack, characterized in that the base frame is attached to the plurality of battery cells by a first thermally conductive adhesive layer.

6. In paragraph 5, A battery pack characterized in that the base frame includes a first cooling channel through which a cooling fluid flows.

7. In paragraph 5, The above pack housing further includes an upper cooling structure disposed on the cell assembly, A battery pack, characterized in that the upper cooling structure is attached to the top plate of the heat transfer structure by a second thermally conductive adhesive layer.

8. In paragraph 7, A battery pack characterized in that the upper cooling structure includes a second cooling channel through which a cooling fluid flows.

9. In paragraph 1, The above heat transfer structure, A plurality of cell receiving spaces separated from each other in a first direction and each extending in a second direction perpendicular to the first direction; and A plurality of venting channels separated from each other in the first direction and each extending in the second direction; Including more, Each of the plurality of cell accommodation spaces accommodates a corresponding battery cell among the plurality of battery cells, A battery pack characterized in that each of the plurality of venting channels is located on a corresponding cell accommodation space among the plurality of cell accommodation spaces and is configured to guide gas in the second direction.

10. In paragraph 9, The above plurality of venting channels each extend in the second direction from the first end to the second end, The cell assembly comprises a blocking plate for closing the first end of each of the plurality of venting channels, A battery pack characterized in that, in each of the plurality of venting channels, gas flows in a direction from the first end of each of the plurality of venting channels toward the second end of each of the plurality of venting channels.

11. In paragraph 10, A battery pack, characterized in that the above blocking plate is a part of the top plate of the above heat transfer structure.

12. In paragraph 10, The above pack housing is, First side walls and second side walls spaced apart in the second direction; and Third side walls and fourth side walls spaced apart in the first direction; Including, Each of the second ends of the plurality of venting channels faces the first side wall, A battery pack characterized in that the third side wall of the pack housing is equipped with a venting device.

13. In paragraph 1, The above plurality of battery cells are arranged in a first direction, The pack housing further includes a base frame supporting the cell assembly and a support structure extending in a second direction perpendicular to the first direction on the base frame, A battery pack characterized in that the cell assembly further includes a fastening frame attached to the outermost battery cell in the first direction among the plurality of battery cells and fastened to the support structure.

14. In paragraph 1, The above pack housing is, a base frame supporting the cell assembly and including a first cooling channel through which a cooling fluid flows; and An upper cooling structure disposed on the cell assembly and including a second cooling channel through which a cooling fluid flows; Including, The above battery pack, a first thermally conductive adhesive layer that attaches the base frame to the plurality of battery cells; and A second thermally conductive adhesive layer attaching the upper cooling structure to the top plate of the heat transfer structure; A battery pack characterized by further including:

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