Battery pack, and vehicle including same

Abstract

The present invention may provide a battery pack including: cell arrays, each including a plurality of battery cells; and a pack case assembly in which a plurality of pack cases are arranged, each pack case accommodating at least one cell array, wherein the cell arrays are configured to be inserted into respective pack cases in a first direction, and the pack cases are configured to be connected in a second direction perpendicular to the first direction.

Description

Battery pack and vehicle including same

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

[0002] This application claims priority to Korean Patent Application No. 10-2024-0115295, filed on August 27, 2024, and all contents disclosed in the specification and drawings of the said application are incorporated herein by reference.

[0003]

[0004] Secondary batteries, which have high applicability according to product group and electrical characteristics such as high energy density, are widely used in portable devices as well as electric vehicles (EVs) or hybrid electric vehicles (HEVs) driven by electrical power sources.

[0005] These secondary batteries are attracting attention as a new energy source for environmental friendliness and energy efficiency, not only because they have the primary advantage of drastically reducing the use of fossil fuels, but also because they produce no byproducts from energy use.

[0006] Commonly used secondary batteries today include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, and nickel-zinc batteries. When high output voltage is required, multiple battery cells are connected in series to form a battery module or battery pack. Furthermore, to increase charge / discharge capacity, multiple battery cells are connected in parallel to form a battery module or pack. Therefore, the number of battery cells included in a battery module or pack can vary depending on the required output voltage or charge / discharge capacity.

[0007] When connecting multiple battery cells in series or parallel to form a battery pack, a common method is to first construct a battery module containing at least one battery cell, and then use this at least one battery module to add other components to form a battery pack or battery rack. In this case, the battery cells are packaged into modules, and the battery modules are packaged into battery packs. Ultimately, they are installed in a vehicle, but only the battery cells are used to supply power. This excessive packaging not only requires the design and production of additional components, but also takes up additional space, which can reduce the space utilization of the battery cells. Furthermore, battery packs in the cell-to-pack form, where multiple battery cells are housed directly in a pack housing, etc., rather than being modularized, are also being manufactured.

[0008] Recently, the capacity of batteries for electric vehicles has been increasing. In order to increase energy density while maintaining vehicle space, there is a need to develop battery packs that maximize space utilization, minimize the number of parts used in the battery pack, and simplify the assembly process.

[0009]

[0010] Accordingly, the problem to be solved by the present invention is to provide a cell-to-chassis type battery pack configured to integrate a battery pack and an automobile chassis and directly mount a cell array on the automobile chassis.

[0011] In addition, the problem to be solved by the present invention is to provide a battery pack with enhanced stability by discharging venting gas, etc. generated by a thermal event, toward the bottom of the battery pack.

[0012] In addition, the problem to be solved by the present invention is to provide a battery pack that is easy to assemble and disassemble, and easy to expand and contract to correspond to the size of a vehicle by simplifying the structure of the pack case and modularizing the case for easy manufacturing.

[0013] In addition, the problem to be solved by the present invention is to provide a battery pack in which a cell array is stored in a pack case in a sliding manner, so that when a defective cell array is stored, it is easy to replace it with another cell array.

[0014] Another problem that the present invention seeks to solve is to provide a vehicle including such a battery pack.

[0015] However, the problems to be solved by the present invention are not limited to the problems described above, and other problems not mentioned can be clearly understood by those skilled in the art from the description of the invention described below.

[0016]

[0017] In order to solve the above problem, the present invention can provide a battery pack including a pack case assembly having a plurality of cell arrays including a plurality of battery cells and a plurality of pack cases configured to accommodate at least one of the cell arrays, wherein the cell arrays are configured to be inserted into the pack cases in a first direction, and the pack cases are configured to be connected in a second direction perpendicular to the first direction.

[0018] The above pack case assembly may be characterized in that it is configured to be directly mounted to the chassis of a vehicle.

[0019] The above pack case may be characterized by having a square tubular shape with an opening formed on the front or back facing the first direction.

[0020] The above cell array may be characterized in that it is configured to slide within the pack case through the opening.

[0021] The above pack case may be characterized in that it is configured to be formed by at least one of extrusion, forging, pressing, and casting methods.

[0022] The pack cases constituting the pack case assembly may be characterized in that they are configured to be welded to each other.

[0023] It may be characterized in that the pack cases are sequentially combined so that the size of the pack case assembly expands in the second direction.

[0024] It may further be characterized by including at least one venting valve arranged to penetrate at least one venting hole formed on one surface of the pack case.

[0025] The above venting valve may be characterized in that it is configured to penetrate the lower plate of the case.

[0026] It may further include a cap configured to cover the above opening and be detachably attached to the pack case.

[0027] The battery cell may further include a busbar assembly electrically connected to the electrode lead, wherein the busbar assembly includes a busbar terminal positioned at the bottom of the battery cell and configured to be coupled to the electrode lead.

[0028] The above busbar assembly may further include a busbar connector configured to connect the busbar terminals arranged within different pack cases, and the busbar connector may be configured to penetrate a hole formed in the cap and be connected from the outside of the cap.

[0029] It may be characterized by further including a side member configured to be directly coupled to the pack case assembly.

[0030] The above side member may be characterized as being a chassis of an automobile.

[0031] And, the present invention provides an automobile including a battery pack according to the present invention.

[0032] In addition, the present invention can provide a vehicle, characterized in that it includes a pack case assembly having a plurality of cell arrays including a plurality of battery cells and a plurality of pack cases configured to accommodate at least one of the cell arrays, wherein the cell arrays are configured to be inserted into the pack cases in a first direction, the pack cases are configured to be connected in a second direction perpendicular to the first direction, and the pack case assembly is configured to be directly mounted on a chassis of the vehicle.

[0033]

[0034] According to one aspect of the present invention, the case assembly and / or side members constituting the battery pack can be directly coupled to the vehicle chassis, or can be utilized as the vehicle chassis itself. In other words, the cell array can be directly mounted on the vehicle chassis. This allows for increased energy density, improved space utilization, reduced weight, and reduced costs, all while maintaining the vehicle's structure and size.

[0035] In addition, according to another aspect of the present invention, directional venting is induced so that venting gas and the like generated by a thermal event can be discharged in the lower direction of the battery pack, so that the pressure and thermal energy inside the battery pack are efficiently discharged, thereby delaying the thermal transfer phenomenon that propagates in a chain to neighboring cell arrays, and enhancing safety.

[0036] Furthermore, according to another aspect of the present invention, the structure of the pack case can be simplified and modularized for ease of manufacture. By sequentially combining multiple modularized pack cases, assembly is simplified, customization is possible for various vehicle sizes, and parts can be shared, reducing costs.

[0037] Furthermore, according to another aspect of the present invention, the cell array can be inserted into the pack case in a sliding manner, making assembly and assembly convenient and simple. Furthermore, if a defective cell array is stored, it can be easily replaced with another cell array.

[0038] In addition, according to another aspect of the present invention, events resulting from thermal runaway in a vehicle including a plurality of battery packs, such as fire or explosion, can be prevented or delayed.

[0039] In addition, the present invention may have various other effects, which will be described in each embodiment configuration, or the description of effects that can be easily inferred by those skilled in the art will be omitted.

[0040]

[0041] The following drawings attached to this specification illustrate preferred embodiments of the present invention, and together with the detailed description of the invention described below, serve to further understand the technical idea of ​​the present invention, and therefore, the present invention should not be interpreted as being limited to matters described in such drawings.

[0042] FIG. 1 is a perspective view of a battery pack viewed from the front according to one embodiment of the present invention.

[0043] FIG. 2 is a perspective view of a battery pack viewed from the rear according to one embodiment of the present invention.

[0044] Figure 3 is an exploded perspective view showing a battery pack separated according to one embodiment of the present invention.

[0045] Figure 4 is a perspective view showing a pack case according to one embodiment of the present invention.

[0046] Figure 5 is a front view showing a pack case according to one embodiment of the present invention.

[0047] FIG. 6 is a drawing showing a cell array inserted into a pack case according to one embodiment of the present invention.

[0048] FIG. 7 is a drawing showing a cell array inserted into a pack case according to one embodiment of the present invention.

[0049] FIG. 8 is a drawing showing a plurality of pack cases arranged according to one embodiment of the present invention.

[0050] FIG. 9 is a perspective view showing a plurality of pack cases and cell arrays according to one embodiment of the present invention.

[0051] FIG. 10 is a perspective view showing a pack case equipped with a venting valve according to one embodiment of the present invention.

[0052] Figure 11 is an exploded perspective view showing a pack case equipped with a venting valve according to one embodiment of the present invention.

[0053] Fig. 12 is a front view showing a pack case equipped with a venting valve according to one embodiment of the present invention.

[0054] FIG. 13 is a perspective view showing a battery pack including a cap according to one embodiment of the present invention.

[0055] FIG. 14 is a perspective view showing a battery pack including a cap according to another embodiment of the present invention.

[0056] FIG. 15 is a perspective view showing a battery pack including a busbar assembly according to one embodiment of the present invention, viewed from the front.

[0057] FIG. 16 is a perspective view showing a battery pack including a busbar assembly according to another embodiment of the present invention, viewed from the rear.

[0058] Fig. 17 is a perspective view showing the lower surface and busbar assembly of a pack case according to one embodiment of the present invention.

[0059] Fig. 18 is a drawing showing a busbar connector according to one embodiment of the present invention.

[0060] FIG. 19 is a drawing showing a busbar assembly positioned on the lower surface of a pack case according to one embodiment of the present invention, viewed from above.

[0061] FIG. 20 is a drawing showing a cell array and a busbar assembly connected according to one embodiment of the present invention.

[0062] FIG. 21 is a drawing showing a portion of a battery pack including a front connector according to one embodiment of the present invention.

[0063] FIG. 22 is a perspective view showing a battery pack including a side member according to one embodiment of the present invention.

[0064] Figure 23 is a perspective view showing a side member according to one embodiment of the present invention.

[0065] Figure 24 is a front view of a cell array inserted into a pack case according to one embodiment of the present invention.

[0066] Figure 25 is a perspective view showing a cell array according to one embodiment of the present invention.

[0067] Figure 26 is a perspective view showing a cell array according to one embodiment of the present invention as viewed from the bottom.

[0068] Figure 27 is an exploded perspective view of a cell array according to one embodiment of the present invention.

[0069] Figure 28 is a perspective view showing an absorbent member according to one embodiment of the present invention.

[0070] Figure 29 is a perspective view showing an absorbent member according to another embodiment of the present invention.

[0071] FIG. 30 is a perspective view showing each absorbent member mounted on a facing cell array according to one embodiment of the present invention.

[0072] FIG. 31 is a side cross-sectional view showing a combined appearance of facing cell arrays and absorbent members according to one embodiment of the present invention.

[0073] FIG. 32 is a schematic drawing of a vehicle including a battery pack according to one embodiment of the present invention.

[0074]

[0075] 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.

[0076] 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.

[0077] Furthermore, the present invention includes various embodiments. For each embodiment, redundant descriptions of substantially identical or similar components will be omitted, and the differences will be described.

[0078] Additionally, to facilitate understanding of the invention, the attached drawings are not drawn to scale and the dimensions of some components may be exaggerated. Furthermore, identical components may be assigned the same reference numbers in different embodiments.

[0079] Although terms like "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are used merely to distinguish one component from another, and unless otherwise specified, a "first" component may also be a "second" component.

[0080] Throughout the specification, unless otherwise specifically stated, each element may be singular or plural.

[0081] Hereinafter, the phrase "any configuration is placed on (or below)" a component or "on (or below)" a component may mean that any configuration is placed in contact with the upper surface (or lower surface) of said component, and that other configurations may be interposed between said component and any configuration placed on (or below) said component.

[0082] Additionally, when it is described that a component is "connected," "coupled," or "connected" to another component, it should be understood that the components may be directly connected or connected to one another, but that other components may also be "interposed" between the components, or that each component may be "connected," "coupled," or "connected" through another component.

[0083] As used herein, singular expressions include plural expressions unless the context clearly dictates otherwise. In this application, terms such as "consisting of" or "comprising" should not necessarily be construed to include all of the components or steps described in the specification, and should be construed to mean that some of the components or steps may not be included, or that additional components or steps may be included.

[0084] Throughout the specification, when reference is made to “A and / or B,” this may mean A, B, or A and B, unless otherwise specifically stated.

[0085] Meanwhile, in this specification, unless otherwise specified, the Y-axis direction in which a plurality of cell arrays are stacked is referred to as the front-back direction, the X-axis direction, which is a horizontal direction orthogonal to the stacking direction of these cell arrays, is referred to as the left-right direction, and the Z-axis direction orthogonal to the XY plane is referred to as the up-down direction (vertical direction). In addition, the left-right direction, the front-back direction, and the up-down direction may also be expressed as the first direction, the second direction, and the third direction, respectively.

[0086] Meanwhile, in this specification, terms indicating directions such as up, down, left, right, front, and back may be used, but these terms are only for convenience of explanation, and it is obvious to those skilled in the art that these terms may vary depending on the position, arrangement, rotation, and position of the object being targeted, or the position of the observer.

[0087] Fig. 1 is a perspective view of a battery pack (10) as viewed from the front (+Y-axis direction) according to one embodiment of the present invention. Fig. 2 is a perspective view of a battery pack (10) as viewed from the rear (-Y-axis direction) according to one embodiment of the present invention. Fig. 3 is an exploded perspective view showing a separated state of a battery pack (10) according to one embodiment of the present invention.

[0088] Referring to FIGS. 1 to 3, a battery pack (10) according to one embodiment of the present invention may include a cell array (100), a pack case assembly (200), a cap (300), a side member (400), a busbar assembly (500), and a venting valve (600).

[0089] The cell array (100) may include a plurality of battery cells (110). The cell array (100) may further include a module cover (120). In this case, according to one embodiment, the cell array (100) may be defined as a battery module.

[0090] A plurality of cell arrays (100) may be provided. The plurality of cell arrays (100) may be stacked on each other. The plurality of cell arrays (100) may be stacked in a horizontal direction. The cell array (100) may have various structures, and furthermore, the plurality of cell arrays (100) may be stacked in various ways. The number and stacking method of the plurality of cell arrays (100) may be designed in various ways depending on the size of the battery accommodation space of the vehicle to which they are applied.

[0091] The pack case assembly (200) may be in the form of a plurality of pack cases (210) arranged in a row. The pack case (210) may be configured to accommodate at least one cell array (100). Specifically, the pack case (210) may have an internal space formed therein and may be configured to accommodate the cell array (100) in the internal space. The pack case (210) may be provided in multiple units. The multiple pack cases (210) may be arranged side by side in one direction.

[0092] According to one embodiment, the pack case assembly (200) may include a first pack case (210), a second pack case (220) disposed next to the first pack case (210), a third pack case (230) disposed next to the second pack case (220), and a fourth pack case (240) disposed next to the third pack case (230). In other words, the first pack case (210), the second pack case (220), the third pack case (230), and the fourth pack case (240) may be sequentially disposed in one direction (X-axis direction). However, the number of pack cases (210) constituting the pack case assembly (200) is not limited by the above embodiment, and may be designed in various ways depending on the size of a battery accommodation space in a vehicle.

[0093] The first pack case (210), the second pack case (220), the third pack case (230), and the fourth pack case (240) have substantially the same structure and shape, and for convenience of explanation, the features encompassing the first pack case (210), the second pack case (220), the third pack case (230), and the fourth pack case (240) are defined as the pack case (210).

[0094] At this time, according to one embodiment, the pack case assembly (200) may be directly mounted to the chassis of the vehicle, or the pack case assembly (200) may be the chassis of the vehicle itself. That is, the cell array (100) may be configured to be inserted and / or mounted directly to the vehicle chassis (e.g., the pack case assembly (200)).

[0095] At this time, the cell array (100) is configured to be inserted in a first direction (Y-axis direction) into a pack case (210), and a plurality of pack cases (210) can be configured to be connected in a second direction (X-axis direction) perpendicular to the first direction.

[0096] Fig. 4 is a perspective view showing a pack case (210) according to one embodiment of the present invention. Fig. 5 is a front view showing a pack case (210) according to one embodiment of the present invention. Fig. 6 is a drawing showing a cell array (100) inserted into a pack case (210) according to one embodiment of the present invention. Fig. 7 is a drawing showing a cell array (100) inserted into a pack case (210) according to one embodiment of the present invention.

[0097] First, referring to FIG. 4, the pack case (210) may have openings (215, 216) formed on the front or the rear. In the embodiment, the pack case (210) is exemplified in that the openings (215, 216) are formed on the front and the rear, respectively. The pack case (210) may have a square tubular shape that is open in the front-back direction (e.g., the Y-axis direction in FIG. 4). For example, the pack case (210) may include a left plate (211) and a right plate (212) that cover one side facing the left direction (e.g., the -X-axis direction in FIG. 4) and one side facing the right direction (e.g., the +X-axis direction in FIG. 4), a lower plate (214) that covers one side facing the lower direction (e.g., the -Z-axis direction in FIG. 4), and an upper plate (213) that covers one side facing the upper direction (e.g., the +Z-axis direction in FIG. 4). In addition, the left plate (211), right plate (212), lower plate (214), and upper plate (213) may be configured in an integrated form. At this time, the front and rear directions of the pack case (210) may be open. That is, the pack case (210) may include both a front opening (215) and a rear opening (216).

[0098] According to the above-described embodiment of the present invention, the cell array (100) can be stored in or removed from the internal space of the pack case (210) through the front opening (215) and / or the rear opening (216) of the pack case (210). Therefore, it is easy to assemble the cell array (100) into the pack case (210), and when a defective cell array (100) is stored, it is easy to replace it with another cell array (100). Therefore, after-sales service (A / S) is possible even in the CTC form.

[0099] In another embodiment, although not shown in the drawing, the pack case (210) may be opened only in either the front direction (e.g., the +Y-axis direction of FIG. 4) or the rear direction (e.g., the -Y-axis direction of FIG. 4). For example, the pack case (210) may further include a rear plate (not shown) covering one side facing the rear. In this case, the front direction of the pack case (210) may be open. That is, the pack case (210) may include a front opening (215), and the cell array (100) may be stored in or removed from the internal space of the pack case (210) through the front opening (215).

[0100] According to another embodiment, although not shown in the drawing, the pack case (210) may be provided as a U-frame. When the pack case (210) is provided as a U-frame, it may be provided to cover both sides and the lower side of the cell array (100). For example, the pack case (210) may include a left plate (211) and a right plate (212) covering one side facing left and one side facing right of the cell array (100), and a lower plate (214) covering one side facing downward of the cell array (100). In addition, the left plate (211), the right plate (212), and the lower plate (214) may be configured in an integrated form. At this time, the upper direction and the front-back direction (e.g., the Y-axis direction of FIG. 4) of the pack case (210) may be open.

[0101] At this time, the pack case (210) may further include a top plate (not shown). The top plate may be provided to form one surface facing upward of the pack case (210). If the pack case (210) is provided as a U-frame, the top plate may be coupled to the open upper side of the pack case (210). The top plate may be welded to the U-frame of the pack case (210) and coupled to each other. However, the top plate may be omitted as needed. For example, the pack case (210) may be provided with the upper side open. However, the shape and / or structure of the pack case (210) is not limited by the above embodiment and may be designed in various ways.

[0102] Referring to FIGS. 4 to 6, the lower plate (214) of the pack case (210) may be formed with a step. That is, the lower plate (214) of the pack case (210) may be divided into regions based on the X-axis, and the height of the plate may be formed differently depending on the region. The lower plate (214) of the pack case (210) may be divided into an edge portion (214a) protruding downward, a center portion (214c) located higher than the edge portion (214a), and a middle portion (214b) located between the edge portion (214a) and the center portion (214c) and higher than the center portion (214c).

[0103] The edge portion (214a), the center portion (214c), and the middle portion (214b) are flat plate-shaped in the horizontal direction, and connecting portions (214d) that connect the edge portion (214a), the center portion (214c), and the middle portion (214b) to each other and are formed to be inclined at a predetermined angle from the horizontal plane may be provided.

[0104] The edge portion (214a) of the lower plate (214) is the lowest among the lower plates (214) and can directly contact the floor surface of the vehicle. In addition, the edge portion (214a) is a portion that protrudes downward and can guide the sliding movement of the cell array (100). The middle portion (214b) of the lower plate (214) can be configured to be the highest among the lower plates (214) and to allow the cell array (100) to be settled thereon. The center portion (214c) of the lower plate (214) can be configured to be coupled with a venting valve (600) to be described later.

[0105] The shape of the lower plate (214) may be symmetrical with respect to the X-axis. The center portion (214c) of the lower plate (214) may be located at the center with respect to the X-axis. The middle portion (214b) of the lower plate (214) may be composed of a plate extending leftward from the center portion (214c) and a plate extending rightward. The edge portion (214a) of the lower plate (214) may be composed of a plate extending leftward from the middle portion (214b) and a plate extending rightward.

[0106] According to the above-described embodiment of the present invention, a step is formed on the lower plate (214) of the pack case (210), so that the cell array (100) can be easily stored and positioned. In addition, when the venting valve (600) described below is mounted on the lower plate (214) of the pack case (210) (e.g., the center portion (214c)), the venting valve (600) can be prevented from directly contacting one surface (the floor surface of the vehicle) outside the pack case (210), thereby protecting the venting valve (600) from the outside.

[0107] The pack case (210) may be formed of a metal material having rigidity and heat resistance to physically or chemically protect the cell array (100) accommodated within the pack case (210). For example, the pack case (210) may include at least one of an aluminum alloy, stainless steel, a titanium alloy, and an amorphous metal. For example, the pack case (210) may include an aluminum alloy.

[0108] According to the above-described embodiment of the present invention, each pack case (210) constituting the pack case assembly (200) forms an independent space, and includes a thick and rigid material (e.g., aluminum), so that the pack case (210) itself acts as a partition wall, thereby preventing heat from being transferred to the cell array in another adjacent pack case.

[0109] The pack case (210) can be formed by one or more of extrusion, forging, pressing, and casting methods. According to one embodiment, the pack case (210) can be formed by extrusion. For example, if the pack case (210) has a hollow structure including a front opening (215) and a rear opening (216), it can be formed into a square tube shape by extrusion. According to the above-described exemplary configuration of the present invention, the manufacturing process is simple and can be efficient in producing a pack case (210) having a consistent shape and a long length. Referring mainly to FIG. 6, the cell array (100) can be inserted into the pack case (210) in a first direction (Y-axis direction). The cell array (100) can be inserted into the pack case (210) only in the first direction. Unlike a typical conventional pack case, it can be configured so that it cannot be inserted in a second direction (X-axis direction) that is perpendicular to the first direction. That is, the pack case (210) can be arranged so that a plurality of cell arrays (100) can be inserted inside it along the first direction. For example, a plurality of cell arrays (100) can be inserted inside the pack case (210) in the front-back direction through the front opening (215) and / or the rear opening (216) of the pack case (210). In other words, it can be a structure in which the cell arrays (100) are inserted in a row inside the pack case (210).

[0110] The cell array (100) may be configured to slide within the pack case (210) through the front opening (215) and / or the rear opening (216). That is, a plurality of cell arrays (100) may be inserted into the pack case (210) in a sliding manner in a first direction. The cell arrays (100) may be inserted in a row within the pack case (210). The cell arrays (100) inserted in a sliding manner may be in close contact with each other. The cell arrays (100) inserted within the pack case (210) may be configured to be in direct contact with each other without a predetermined gap.

[0111] Conventionally, battery modules are assembled by vertically mounting each module in a pack case, and a gap (clearance) must be provided between the battery modules for assembly. According to the present invention, by inserting the cell array (100) in a row inside the pack case (210), the cell array (100) can be assembled without gaps between the cell arrays (100).

[0112] According to the above-described embodiment of the present invention, the cell array (100) can be inserted into the pack case (210) through sliding movement, making assembly and bonding convenient and simple. Furthermore, if a defective cell array (100) is stored, it can be easily replaced with another cell array (100). Therefore, post-management is possible even in the CTC form. Furthermore, the cell arrays (100) can be brought into close contact with each other, maximizing energy density.

[0113] At this time, the number of cell arrays (100) inserted into the pack case (210) can be designed in various ways. For example, referring to FIGS. 6 and 7, three cell arrays (100) can be inserted into the pack case (210). That is, considering the battery insertion space in the vehicle, if N cell arrays (100) can be inserted in the Y-axis direction, the pack case (210) can be manufactured with a length in which N cell arrays (100) can be inserted. Since the length of the pack case (210) can be adjusted, it can have a flexible size for each vehicle, and can be manufactured as a battery pack (10) of a flexible size.

[0114] Referring primarily to FIG. 7, the horizontal length (X-axis length) (T2) of the pack case (210) may correspond to the horizontal length (X-axis length) (T1) of the cell array (100). The horizontal length (X-axis length) (T2) of the pack case (210) may be substantially the same as the horizontal length (X-axis length) (T1) of the cell array (100), or may be formed to be somewhat longer than the horizontal length (X-axis length) (T1) of the cell array (100) to facilitate insertion and mounting.

[0115] The height (Z-axis length) (H2) of the pack case (210) may correspond to the height (Z-axis length) (H1) of the cell array (100). The height (Z-axis length) (H2) of the pack case (210) may be substantially the same as the height (Z-axis length) (H1) of the cell array (100), or may be formed to be somewhat longer than the height (Z-axis length) (H1) to facilitate insertion and mounting.

[0116] The vertical length (Y-axis length) (L2) of the pack case (210) may correspond to N times (N: the number of cell arrays (100) inserted) the vertical length (Y-axis length) (L1) of the cell array (100). The vertical length (Y-axis length) (L2) of the pack case (210) may be substantially equal to N times the vertical length (Y-axis length) (L1) of the cell array (100), or may be formed to be somewhat longer than that to facilitate insertion and mounting. For example, referring to FIG. 7, when three cell arrays (100) are configured to be inserted into the pack case (210), the vertical length (Y-axis length) (L2) of the pack case (210) may be substantially equal to three times the vertical length (Y-axis length) (L1) of the cell array (100).

[0117] According to the above-described embodiment of the present invention, the pack case (210) may be formed to have a size and length corresponding to the cell array (100), and may be formed to be extended in the first direction so that the cell array (100) can be inserted in the first direction. This simplifies the structure of the pack case (210) and modularizes the pack case (210) for ease of manufacture. The modularized pack case (210) may be applicable to automobiles of various sizes.

[0118] Fig. 8 is a drawing showing a plurality of pack cases (210) arranged according to one embodiment of the present invention. Fig. 9 is a perspective view showing a plurality of pack cases (210) and a cell array (100) according to one embodiment of the present invention.

[0119] A plurality of pack cases (210) may be provided. The plurality of pack cases (210) may be configured to be connected in one direction. At this time, a configuration in which the plurality of pack cases (210) are arranged may be defined as a pack case assembly (200). The plurality of pack cases (210) may be configured to be connected in a second direction (X-axis direction) that is perpendicular to the first direction. The plurality of pack cases (210) may be stacked in the second direction.

[0120] At this time, the number of pack cases (210) constituting the pack case assembly (200) can be designed in various ways. That is, when M pack cases (210) (or cell arrays (100)) can be inserted in the X-axis direction in consideration of the battery insertion space in the vehicle, the M pack cases (210) can be configured to be lined up. For example, referring to FIGS. 8 and 9, four pack cases (210) can be lined up. For example, the pack case assembly (200) can be provided with a first pack case (210), a second pack case (220), a third pack case (230), and a fourth pack case (240). The first pack case (210), the second pack case (220), the third pack case (230), and the fourth pack case (240) can be sequentially lined up in the X-axis direction. In this way, since the number of pack cases (210) can be adjusted, it is possible to manufacture a battery pack (10) of a flexible size by having a flexible size for each vehicle.

[0121] A plurality of pack cases (210) can be combined and integrated. A plurality of pack cases (210) constituting a pack case assembly (200) can be configured to be joined to each other by welding. For example, a method such as laser welding, ultrasonic welding, or friction stir welding can be used, but various other joining methods can also be applied. A plurality of pack cases (210) arranged side by side can be configured to be joined by welding in a 1:1 ratio. Referring to a portion indicated by A in FIG. 8, the right side plate (212) of the first pack case (210) and the left side plate (211) of the second pack case (220) facing each other can be welded to each other. The welded portion (W) can extend in the Y-axis direction along both sides of the pack cases (210).

[0122] According to the above-described embodiment of the present invention, a plurality of pack cases (210) can be sequentially connected so that the length and size of the pack case assembly (200) can be expanded in the second direction. In addition, the welding method can be adopted to facilitate and simplify the joining and assembly. By combining modular pack cases (210), the size can be flexibly adjusted to fit various sizes of automobiles.

[0123] Fig. 10 is a perspective view showing a pack case (210) equipped with a venting valve (600) according to one embodiment of the present invention. Fig. 11 is an exploded perspective view showing a pack case (210) equipped with a venting valve (600) according to one embodiment of the present invention. Fig. 12 is a front view showing a pack case (210) equipped with a venting valve (600) according to one embodiment of the present invention.

[0124] Referring to FIGS. 10 to 12, the battery pack (10) may further include at least one venting valve (600) arranged to penetrate at least one venting hole (217) formed on one surface of the pack case (210).

[0125] The venting valve (600) may be configured to penetrate the lower plate (214) of the pack case (210). The venting valve (600) may be positioned to penetrate the center portion (214c) of the lower plate (214). A venting hole (217) may be formed in the center portion (214c) of the lower plate (214) of the pack case (210). That is, the venting valve (600) may be coupled and fixed to the lower plate (214) by penetrating the venting hole (217).

[0126] A plurality of venting valves (600) may be combined within a pack case (210). For example, a plurality of venting valves (600) may be arranged in the Y-axis direction. The plurality of venting valves (600) may be arranged to be spaced apart from each other at predetermined intervals. Similarly, a plurality of venting holes (217) may be provided, and the plurality of venting holes (217) may be arranged in the Y-axis direction to correspond to the positions of the venting valves (600). For example, referring to FIG. 11, five venting valves (600) may be combined in one pack case (210), and five venting holes (217) may be formed.

[0127] In the past, the battery pack case was configured to vent in the lateral direction, and if the venting gas was discharged toward the internal components of the vehicle, there was a problem with the stability of other components. According to the above-described embodiment of the present invention, the venting gas, etc. generated by a thermal event can be guided to be discharged in the downward direction of the battery pack (10) without being obstructed or blocked by structures such as the vehicle body or chassis provided adjacent to the battery pack (10).

[0128] Therefore, before heat energy accumulates due to discharge inside the battery pack (10), venting gas and the like can be smoothly and quickly discharged to the outside of the vehicle. As the pressure and heat energy inside the battery pack (10) are efficiently discharged, the heat transfer phenomenon that is serially transmitted to the neighboring cell array (100) is delayed, and safety can be enhanced.

[0129] The venting valve (600) is positioned adjacent to the battery cell (110) and / or the electrode lead (111), so as to minimize heat transfer to the adjacent battery cell (110). The edge portion (214a) of the lower plate (214) has the lowest height among the lower plates (214) and can be in direct contact with the floor of the vehicle. At this time, the center portion (214c) to which the venting valve (600) is coupled has a height higher than the edge portion (214a), so as to prevent the venting valve (600) from being in direct contact with the floor of the vehicle. Accordingly, the venting valve (600) can be prevented from being damaged by direct contact with the floor of the vehicle, etc.

[0130] The middle portion (214b) of the lower plate (214) may be configured to have the highest height among the lower plates (214) so ​​that the cell array (100) may be settled thereon. The center portion (214c) may be lower in height than the middle portion (214b), thereby preventing the cell array (100) from being lifted by the venting valve (600).

[0131] According to the present invention, when thermal runaway occurs in a battery cell (110), gas or flame generated inside the battery cell (110) can be discharged to the outside of the cell array (100) through the lower portion of the battery cell (110). Specifically, directional venting can be induced toward the lower portion of the cell array (100). Gas or flame generated in the battery cell (110) is not discharged through the upper portion of the battery cell (110) but can be directly discharged through the venting valve (600) located at the lower portion of the battery cell (110) adjacent to the battery cell (110), thereby enhancing safety. Cooling of the battery cell (110) can be performed at the upper portion opposite the venting valve (600) so as not to interfere with downward venting.

[0132] Fig. 13 is a perspective view showing a battery pack (10) including a cap (300) according to one embodiment of the present invention. Fig. 14 is a perspective view showing a battery pack (10) including a cap (300) according to another embodiment of the present invention.

[0133] The battery pack (10) may further include a cap (300) configured to cover the openings (215, 216) of the pack case (210). That is, the cap (300) may cover one side facing the front and / or the rear of the pack case (210). According to one embodiment, the pack case (210) may be formed with a front opening (215) and a rear opening (216), and the cap (300) may include a front cap (310) configured to cover the front opening (215) and a rear cap (320) configured to cover the rear opening (216).

[0134] The shape of the cap (300) may be substantially the same as the front shape of the pack case assembly (200). That is, the cap (300) may be configured to cover a plurality of openings (215 or 216) of a plurality of pack cases (210) constituting the pack case assembly (200) at once. The horizontal length (X-axis length) of the cap (300) may be substantially the same as the horizontal length (X-axis length) of the pack case assembly (200). For example, referring to FIG. 13, when there are four pack cases (210) constituting the pack case assembly (200), the cap (300) may be substantially the same as four times the horizontal length (X-axis length) of the pack cases (210). The height (Z-axis length) of the cap (300) may be substantially the same as the height (Z-axis length) of the pack case assembly (200) (pack case (210)). The lower surface of the cap (300) may be provided with a vertically protruding or concave shape, like the lower plate (214) of the pack case (210).

[0135] The cap (300) may include a plurality of holes (301). The number of holes (301) formed in the cap (300) may correspond to the number of pack cases (210) constituting the pack case assembly (200). For example, referring to FIG. 13, when there are four pack cases (210) constituting the pack case assembly (200), four holes (301) may be arranged to be spaced apart from each other in the X-axis direction. In addition, each hole (301) may be formed at a position corresponding to an opening (215 or 216) of each pack case (210). Specifically, the hole (301) may be formed at a position corresponding to a bus bar connector (520) connected to each pack case (210). The bus bar connector (520) connected to each pack case (210) may pass through the hole (301) and be connected to the outside of the pack case (210).

[0136] The cap (300) may be configured to be attached to and detached from the pack case (210). According to one embodiment, the cap (300) may be provided with an adhesive at an edge portion that comes into contact with the pack case (210). At this time, the adhesive strength of the adhesive is suitably about 0.1 gf / 25 mm to 500 gf / 25 mm, and more preferably 1 gf / 25 mm to 100 gf / 25 mm. Since this is lower than the adhesive strength of a general adhesive of 1,500 gf / 25 mm, it is distinguished from a general adhesive and can be easily attached and detached. However, the configuration of the cap (300) is not limited by the above embodiment, and if the cap (300) is configured to be attached and detached from the pack case (210), the design may be changed in various ways.

[0137] According to the above-described embodiment of the present invention, the cap (300) covers the front and rear sides of the pack case (210) to reinforce the structural rigidity of the cell array (100) and prevent the venting gas from being transferred to another pack case (210) through the front or rear side of the pack case (210). The cap (300) is detachable from the pack case (210), so that separation from the pack case (210) is simple, and the cell array (100) within the pack case (210) can be easily replaced.

[0138] According to another embodiment, referring to FIG. 14, the front cap (310) and the rear cap (320) may have a plurality of caps (300) configured to cover a plurality of pack cases (210), respectively. That is, the caps (300) may individually cover the openings (215 or 216) of the pack cases (210). For example, referring to FIG. 14, the front cap (310) may include a first front cap (311) covering the first pack case (210), a second front cap (312) covering the second pack case (220), a third front cap (313) covering the third pack case (230), and a fourth front cap (314) covering the fourth pack case (240). Similarly, the rear caps (320) may be configured in four pieces.

[0139] At this time, the shape of the cap (300) may be substantially the same as the front shape of the pack case (210). The horizontal length (X-axis length) of the cap (300) may be substantially the same as the horizontal length (X-axis length) of the pack case (210). The height (Z-axis length) of the cap (300) may be substantially the same as the height (Z-axis length) of the pack case assembly (200) (pack case (210)). The lower surface of the cap (300) may be formed with a protruding structure and a concave structure identical to the lower plate (214) of the pack case (210).

[0140] The cap (300) may include at least one hole (301). The hole (301) may be formed at a position corresponding to an opening of the pack case (210). Specifically, the hole (301) may be formed at a position corresponding to a bus bar connector (520) connected to the pack case (210). The bus bar connector (520) connected to the pack case (210) may pass through the hole (301) and be connected to the outside of the pack case (210).

[0141] According to the above-described embodiment of the present invention, individual caps (300) covering each pack case (210) can be provided so that they can be individually attached and detached. This allows only the caps (300) of the pack cases (210) having cell arrays (100) requiring replacement to be attached and detached. In addition, since standardized caps (300) can be manufactured in batches without adjusting the length or number of holes (301) to suit the size of the vehicle, it can be effective in mass production and cost reduction, and has the advantage of commonization of parts.

[0142] FIG. 15 is a perspective view showing a front view of a battery pack (10) including a busbar assembly (500) according to an embodiment of the present invention. FIG. 16 is a perspective view showing a rear view of a battery pack (10) including a busbar assembly (500) according to an embodiment of the present invention. FIG. 17 is a perspective view showing a lower surface of a pack case and a busbar assembly (500) according to an embodiment of the present invention. FIG. 18 is a view showing a busbar connector (520) according to an embodiment of the present invention. FIG. 19 is a view showing a top view of a busbar assembly (500) arranged on a lower surface of a pack case according to an embodiment of the present invention. FIG. 20 is a view showing a cell array (100) and a busbar assembly (500) connected according to an embodiment of the present invention. FIG. 21 is a view showing a part of a battery pack (10) including a front connector (530) according to an embodiment of the present invention.

[0143] For convenience of explanation, FIGS. 17 and 19 are drawings in which the remaining portion of the pack case (210) except for the lower plate (214) is omitted.

[0144] The busbar assembly (500) may be configured to be electrically connected to the electrode leads (111) of the battery cells (110). The busbar assembly (500) may be configured to enable the electrode leads (111) of a plurality of battery cells (110) to be connected to each other. More specifically, the busbar assembly (500) may be configured to support the electrode leads (111), facilitate the interconnection of the electrode leads (111), and enable sensing of voltage, etc. from the electrode leads (111). The busbar assembly (500) may be configured to enable high voltage connection.

[0145] A busbar assembly (500) may include a busbar terminal (510), a busbar connector (520), and a front connector (530). The busbar terminal (510) may electrically connect two or more electrode leads (111). The busbar terminal (510) may electrically connect two or more electrode leads (111) within one pack case (210).

[0146] Referring to FIG. 20, each battery cell (110) may be provided with an electrode lead (111). The electrode lead (111) of the battery cell (110) includes a positive electrode lead (111a) and a negative electrode lead (111b), and the positive electrode lead (111a) and the negative electrode lead (111b) may be spaced apart from each other and arranged on the lower surface of the battery cell (110). The electrode lead (111) may be provided to protrude downward from the lower surface of the battery cell (110). The specific structure and configuration of the battery cell will be described later.

[0147] The busbar terminal (510) may be positioned at the bottom of the battery cell (110) where the electrode leads (111) of the battery cell (110) are positioned, and may be configured to be coupled with the electrode leads (111). The busbar terminal (510) may be positioned between the bottom of the battery cell (110) and the lower plate (214) of the pack case (210). The busbar terminal (510) may be in vertical contact with a plurality of electrode leads (111) and may be coupled and fixed with the plurality of electrode leads (111). At this time, a method of coupling and fixing between the electrode leads (111) and the busbar terminal (510) may be used, such as laser welding or ultrasonic welding.

[0148] In another embodiment, although not shown in the drawing, a slit hole (not shown) may be formed in the bus bar terminal (510), and the electrode lead (111) may be inserted therethrough and welded. However, the method of fixing and connecting the electrode lead (111) and the bus bar terminal (510) is not limited to the above embodiment, and various other fastening methods may be applied.

[0149] The busbar terminal (510) can be connected to a plurality of electrode leads (111) arranged along the first direction (Y-axis direction), which is the stacking direction of the battery cells (110). For example, referring to FIG. 20, the busbar terminal (510) can connect six electrode leads (111). However, the number of electrode leads (111) that the busbar terminal (510) can connect is not limited by the above embodiment, and can be designed in various ways.

[0150] A plurality of bus bar terminals (510) may be aligned along a first direction (Y-axis direction), which is a stacking direction of the battery cells (110). A plurality of positive bus bar terminals (511) connecting a plurality of positive leads (111a) and a plurality of negative bus bar terminals (512) connecting a plurality of negative leads (111b) may be provided within the pack case (210). The positive bus bar terminals (511) and the negative bus bar terminals (512) may each be aligned along the first direction (Y-axis direction).

[0151] At this time, the positive bus bar terminal (511) and the negative bus bar terminal (512) can connect the electrode leads (111) of different battery cells (110). That is, the positive bus bar terminal (511) can connect the electrode leads (111) from the first battery cell (110) to the sixth battery cell (110), and the negative bus bar terminal (512) can connect the electrode leads (111) from the fourth battery cell (110) to the ninth battery cell (110). According to the above-described embodiment of the present invention, all battery cells (110) accommodated in the pack case (210) can be electrically connected.

[0152] The busbar terminal (510) may include a metal such as copper. The busbar terminal (510) may have a thin, flat plate shape. For example, the busbar terminal (510) may have a rectangular shape.

[0153] The busbar connector (520) can electrically connect busbar terminals (510) arranged in different pack cases (e.g., 210, 220). That is, one end and the other end of the busbar connector (520) can be arranged in different pack cases (e.g., 210, 220).

[0154] A plurality of busbar connectors (520) may be provided. For example, referring to FIG. 17, the busbar connector (520) may include a first connector (521) connecting a busbar terminal (510) of a second pack case (220) and a busbar terminal (510) of a third pack case (230), a second connector (522) connecting a busbar terminal (510) of the first pack case (210) and a busbar terminal (510) of a fourth pack case (240), a third connector (523) connecting a busbar terminal (510) of the third pack case (230) and a busbar terminal (510) of the fourth pack case (240), and a fourth connector (524) connecting a busbar terminal (510) of the first pack case (210) and a busbar terminal (510) of the second pack case (220). According to the above-described embodiment of the present invention, all bus bar terminals (510) constituting the pack case assembly (200) can be electrically connected.

[0155] Referring to FIG. 18, the busbar connector (520) may include a plurality of bending portions. For example, the busbar connector (520) may be positioned on the lower side of the battery cell (110) and include a first portion (5201) extending in a first direction (Y-axis direction), a second portion (5202) extending in a vertical direction (+Z-axis direction) from the first portion (5201), a third portion (5203) extending in a second direction (X-axis direction) from the second portion (5202), a fourth portion (5204) extending in a vertical direction (-Z-axis direction) again from the third portion (5203), and a fifth portion (5205) extending in a first direction (Y-axis direction) from the fourth portion (5204).

[0156] Referring mainly to the enlarged view of FIG. 19, the busbar connector (520) may be configured to be connected on the outside of the cap by penetrating the hole (301) formed in the cap (300). That is, the middle portion of the busbar connector (520) may be disposed outwardly with respect to the cap (300), and the edge portion may be disposed inwardly with respect to the cap (300). For example, the first portion (5201) and the fifth portion (5205) of the busbar connector (520) may be disposed approximately inwardly of the cap (300), and the first portion (5201) and the fifth portion (5205) may penetrate the hole (301) formed in the cap (300). In addition, the second portion (5202), the third portion (5203), and the fourth portion (5204) of the busbar connector (520) may be disposed in the outward direction of the cap (300). The second portion (5202), the third portion (5203), and the fourth portion (5204) may be arranged parallel to the cap (300). In one embodiment, the second portion (5202), the third portion (5203), and the fourth portion (5204) may be in contact with the cap (300).

[0157] According to the above-described embodiment of the present invention, the busbar connector (520) is configured to be connected externally, so that when a thermal event occurs, a heat transfer phenomenon that is serially transmitted to a neighboring pack case (210) through the busbar connector (520) can be prevented, and safety can be enhanced.

[0158] The front connector (530) may be configured to be connected to one or more electrode leads (111) to transmit sensing information to a control unit such as a battery management system (BMS). The front connector (530) may be disposed on a busbar connector (520). The front connector (530) may be electrically connected to the busbar connector (520). For example, the front connector (530) may be disposed on a first connector (521) and electrically connected to the first connector (521).

[0159] The front connector (530) may be arranged to penetrate the cap (300). The front connector (530) may include a plate portion (531) arranged on the cap (300), a connector portion (532) protruding from the front of the plate portion (531) and configured to be connected to external components (e.g., a control unit such as a BMS), and a fixing portion (not shown) configured to be coupled and fixed to the pack case (210). At this time, the plate portion (531) is configured to be coupled and fixed to the cap (300) and may be arranged on the outside of the cap (300). The connector portion (532) may be arranged on the outside of the cap (300). The fixing portion may be seated on one surface within the pack case (210) by penetrating the cap (300). The coupling and fixing method of the plate portion (531) may be fixed using bolts and screws. However, the coupling and fixing method is not limited to the above embodiment and may be designed in various ways.

[0160] Fig. 22 is a perspective view showing a battery pack (10) including a side member (400) according to one embodiment of the present invention. Fig. 23 is a perspective view showing a side member (400) according to one embodiment of the present invention.

[0161] The battery pack (10) may further include a side member (400). The side member (400) may be configured to be directly coupled to the pack case assembly (200).

[0162] The side member (400) can be directly coupled to both sides of the pack case assembly (200). The side member (400) can include a first side member (410) positioned on the left side of the pack case assembly (200) and a second side member (420) positioned on the right side of the pack case assembly (200).

[0163] Referring to FIG. 23, the side member (400) may include a first side surface (401) configured to contact one side of the pack case (210), and a second side surface (402) configured to be coupled with the frame of the vehicle. In one embodiment, the side member (400) may be directly connected to the chassis of the vehicle. In another embodiment, the side member (400) may be the chassis of the vehicle. That is, the side member (400) may be the chassis of the vehicle itself.

[0164] Typically, a battery module is housed in a battery pack (10) and the battery pack (10) is assembled to a vehicle chassis. However, this increases the number of unnecessary components and has disadvantages in terms of space utilization and energy efficiency. According to the above-described embodiment of the present invention, the side member (400) can be directly connected to the vehicle chassis or utilized as the vehicle chassis itself. This allows for increased energy density, improved space utilization, and reduced costs while maintaining the vehicle's structure and size.

[0165] In addition, by adjusting the length and number of pack cases (210), the pack case assembly (200) has the advantage of being able to have a flexible size for each vehicle while allowing the side members (400) to be used as common parts.

[0166] The side member (400) can be coupled to a pack case (e.g., 210, 240) located at an edge of the pack case assembly (200). For example, referring to FIG. 22, the first side member (410) can be coupled to the first pack case (210), and the second side member (420) can be coupled to the fourth pack case (240).

[0167] FIG. 24 is a front view of a cell array (100) according to one embodiment of the present invention inserted into a pack case (210). FIG. 25 is a perspective view of a cell array (100) according to one embodiment of the present invention. FIG. 26 is a perspective view of a cell array (100) according to one embodiment of the present invention viewed from below. FIG. 27 is an exploded perspective view of a cell array (100) according to one embodiment of the present invention. FIG. 28 is a perspective view of an absorbent member (140) according to one embodiment of the present invention. FIG. 29 is a perspective view of an absorbent member (140) according to another embodiment of the present invention. FIG. 30 is a perspective view of each absorbent member (140) mounted on an opposing cell array (100) according to one embodiment of the present invention. Figure 31 is a side cross-sectional view showing a combined appearance of facing cell arrays (100) and absorbent members (140) according to one embodiment of the present invention.

[0168] Referring to FIGS. 24 to 31, the cell array (100) may include a battery cell (110), a module cover (120), and an absorbent member (140).

[0169] The battery cell (110) may be of various types. For example, the battery cell (110) may include at least one of a pouch-type battery cell, a cylindrical battery cell, and a square battery cell. However, for convenience of explanation, the following description focuses on the case where the battery cell (110) is a pouch-type battery cell.

[0170] The battery cell (110) may be provided in multiple units. The multiple battery cells (110) may be stacked on top of each other. The battery cells (110) may have various structures, and furthermore, the multiple battery cells (110) may be stacked in various ways. A pad may be included between the battery cells (110) to prevent movement of the battery cells. The pad may perform substantially the same function as the absorbent member (140).

[0171] The battery cell (110) may have a structure in which a plurality of unit cells arranged in the order of positive plate-separator-negative plate or bi-cells arranged in the order of positive plate-separator-negative plate-separator-positive plate-separator-negative plate are stacked according to the battery capacity.

[0172] The battery cell (110) may be equipped with an electrode lead (111). The electrode lead (111) is a type of terminal that is exposed to the outside and connected to an external device, and may be made of a conductive material. The electrode lead (111) may include a positive lead (111a) and a negative lead (111b).

[0173] The electrode lead (111) may be provided to protrude downward from the lower surface of the battery cell (110). The positive electrode lead (111a) and the negative electrode lead (111b) may be spaced apart from each other and arranged on the lower surface of the battery cell (110). The positive electrode lead (111a) and the negative electrode lead (111b) may be electrically connected to a bus bar terminal arranged on the lower surface of the battery cell (110), respectively. However, the position and shape of the electrode lead (111) are not limited by the above embodiment and may be designed in various ways.

[0174] High-temperature gases, flames, sparks, etc. generated during thermal runaway in the battery cell (110) are highly likely to be ejected toward the portion where the corresponding electrode leads (111) are located (e.g., downward of the battery cells (110)). According to the above-described embodiment of the present invention, by providing the electrode leads (111) at the lower side, directional venting can be induced so that venting gases, etc. are vented downward when a thermal event occurs.

[0175] At this time, the electrode lead (111) and the venting valve (600) may be arranged adjacently. Accordingly, the venting gas, etc. vented downwards, can be quickly discharged to the outside of the battery pack (10) through the venting valve (600) arranged at the bottom. By minimizing the path along which the venting gas, etc. moves within the pack case (210) to the venting valve (600), heat transfer within the pack case (210) or between pack cases (210) can be prevented.

[0176] The module cover (120) may be configured to protect and / or support the battery cells (110). A plurality of battery cells (110) may be stacked and stored in the module cover (120). The module cover (120) surrounds at least a portion of the plurality of battery cells (110), thereby protecting the battery cells (110) from external vibrations or shocks.

[0177] The module cover (120) may further include a top cover (121) that covers the battery cells (110) from the upper side, a front cover (124) that covers the front side, and a rear cover (125) that covers the rear side. The front cover (124) and the rear cover (125) cover the front and rear sides of the battery cells (110) within the cell array (100), thereby supplementing structural rigidity and responding to swelling of the battery cells (110).

[0178] The module cover (120) may include support members (122, 123) that support the battery cells (110) from the bottom. However, the support members (122, 123) may be configured so that at least a portion of the lower portion of the battery cells (110) is not covered, and at least a portion of the lower portion of the battery cells (110) is exposed to the outside. In other words, the electrode leads (111) arranged on the lower surface of the battery cells (110) may not be covered by the module cover (120).

[0179] According to the above embodiment of the present invention, by exposing at least a portion of the lower portion of the battery cell (110), when thermal runaway occurs in the battery cell (110), gas or flame generated inside the battery cell (110) can be discharged to the outside of the cell array (100) through the lower portion of the battery cell (110). Specifically, directional venting can be induced toward the lower side of the cell array (100).

[0180] The support members (122, 123) may be composed of a first bar (122) and a second bar (123) that support the battery cells (110) from the lower sides (left and right). The first bar (122) and the second bar (123) may be shaped like rods that extend long in the first direction (Y-axis direction). The first bar (122) and the second bar (123) may be arranged on the left and right sides of the battery cells (110), respectively. That is, the battery cells (110) may be mounted on the first bar (122) and the second bar (123).

[0181] In another embodiment, although not shown in the drawing, the module cover (120) may include a bottom cover that covers the battery cell (110) from the lower side and has an opening formed in the center portion excluding the edge portion.

[0182] The front cover (124) and the rear cover (125) may be configured to cover all of the top cover (121), the battery cell (110), and the support members (122, 123). For example, referring to FIG. 27, the front cover (124) and the rear cover (125) may have a shape that includes a portion protruding downward so as to correspond to the position and shape of the support members (122, 123) on a rectangular plate. In other words, the lower surfaces of the front cover (124) and the rear cover (125) may have a shape in which the edge portions protrude and the middle portions are concave. In addition, referring to FIG. 24, the protruding edge portions of the front cover (124) and the rear cover (125), that is, the portions where the first bar (122) and the second bar (123) are located, may be configured to be inserted into the edge portion (214a) of the pack case (210) and slide. The middle part of the front cover (124) and the rear cover (125) can be inserted into the middle part (214b) and the center part (214c).

[0183] According to the above-described embodiment of the present invention, it is possible to guide the cell array (100) to slide inside the pack case (210). In addition, it is possible to prevent the cell array (100) from moving inside the pack case (210) and to fix the position of the cell array (100).

[0184] The structure and shape of the module cover (120) supporting the battery cell (110) are not limited to the above embodiment, and some components of the module cover (120) may be removed to reduce the weight and volume of the module cover (120).

[0185] In this way, the module cover (120) can be configured to minimize the weight and volume of the module cover (120) while protecting and / or supporting the battery cells (110) to a minimum. The module cover (120) can minimize the weight and volume by exposing at least a portion of the battery cells (110). For example, referring to FIGS. 25 and 26 , the module cover (120) may not cover at least a portion of both sides and / or the bottom surface of the battery cells (110). That is, at least a portion of both sides and / or the bottom surface of the battery cells (110) may be configured to be exposed. Therefore, the structural rigidity of the module cover (120) may be weaker than the structural rigidity of the pack case (210).

[0186] According to the above-described embodiment of the present invention, the battery cell (110) is protected and supported by a rigid pack case (210), and the portion additionally covered by the module cover (120) can be minimized. In this way, the battery cell (110) can be stored in the space previously occupied by the module case, pack case, etc. of the cell array (100) within the battery pack (10), thereby increasing space efficiency and improving battery capacity. In addition, the energy density can be maximized, the weight of the battery pack (10) can be reduced, and costs can be reduced.

[0187] The module cover (120) can be manufactured, for example, by bending a metal plate, thereby enabling the module cover (120) to be manufactured as an integral part. If the module cover (120) is manufactured as an integral part, the joining process can be simplified and simplified. Alternatively, the module cover (120) can be provided in a detachable form and joined by welding or the like. However, the material of the module cover (120) is not limited to a metal material.

[0188] The top cover (121), front cover (124), rear cover (125), and support members (122, 123) constituting the module cover (120) may be fixedly coupled to each other. For example, the top cover (121), the first bar (122), and the second bar (123) may have protrusions (126) protruding toward the front and rear. In addition, the front cover (124) and the rear cover (125) may be provided with first fixing holes (127) corresponding to the size and shape of the protrusions (126) at portions corresponding to the protrusions (126). At this time, the front cover (124) and the rear cover (125) may each be formed with four first fixing holes (127). Each protrusion (126) may be fitted into its corresponding first fixing hole (127). However, the sizes and shapes of the plurality of protrusions (126) and the first fixing holes (127) may be different from each other. The method of fixing and combining the module cover (120) is not limited to the above embodiment, and various other fastening methods may be applied.

[0189] The absorbent member (140) can be placed on the front cover (124) and the rear cover (125).

[0190] The absorbent member (140) can be directly coupled to the module cover (120). Second fixing holes (144) corresponding to the size and shape of the protrusions (126) formed on the top cover (121) and the support members (122, 123) of the module cover (120) can be provided at portions corresponding to the protrusions (126). At this time, the absorbent member (140) can be formed with four second fixing holes (144). Each protrusion (126) can be fitted into its corresponding second fixing hole (144). However, the sizes and shapes of the plurality of second fixing holes (144) can be different from each other. The method of coupling and fixing the module cover (120) and the absorbent member (140) is not limited to the above embodiment, and various other fastening methods may be applied.

[0191] The absorbent member (140) may include a front absorbent member (140a) disposed on the front of the battery cells (110) and a rear absorbent member (140b) disposed on the rear of the battery cells (110). The front absorbent member (140a) may be disposed on the front cover (124), and the rear absorbent member (140b) may be disposed on the rear cover (125).

[0192] Referring to FIG. 29, the respective absorbent members (140) of the facing cell arrays (100) inserted into one pack case (210) may face each other. The respective absorbent members (140) of the facing cell arrays (100) inserted into one pack case (210) may be configured to contact each other. That is, the rear absorbent member (140b) of the cell array (100) disposed at the front and the front absorbent member (140a) of the cell array (100) disposed at the rear may be disposed to face each other. At least a portion of the rear absorbent member (140b) of the cell array (100) disposed at the front and the front absorbent member (140a) of the cell array (100) disposed at the rear may be in direct contact with each other.

[0193] In this way, when the cell arrays (100) are inserted by sliding into the pack case (210), the cell arrays (100) cannot help but come into direct contact with each other. In the process, a collision between the cell arrays (100) may occur or movement of components or battery cells (110) inside the cell array (100) may occur. The absorbent member (140) of the present invention may be configured to prevent movement of the battery cells (110) or components inside the cell array (100) and absorb shock caused by a collision between the cell arrays (100). In addition, the absorbent member (140) may offset or absorb assembly tolerances between the cell arrays (100). The absorbent member (140) covers the front and rear of the battery cells (110) inside the cell array (100), thereby supplementing structural rigidity and responding to swelling of the battery cells (110).

[0194] The absorbent member (140) may include a body portion (142) that is upright and flat in the vertical direction, and a shock absorbing portion (141) extending from the body portion (142).

[0195] The shock absorbing portion (141) may protrude outwardly from the body portion (142). The shock absorbing portion (141) may be the portion that first comes into contact with the adjacent cell array (100). For example, the shock absorbing portion (141) of the front absorbing member (140a) may protrude forward from the body portion (142). The shock absorbing portion (141) of the rear absorbing member (140b) may protrude backward from the body portion (142).

[0196] According to the above-described embodiment of the present invention, when the shock absorbing part (141) first comes into contact with the adjacent cell array (100) and absorbs the shock resulting from the contact, the shock applied to the battery cell (110) and internal components is reduced, thereby preventing movement of the battery cell (110), etc.

[0197] The shock absorbing portion (141) may be provided in multiple pieces. The multiple shock absorbing portions (141) may be evenly arranged over the entire area of ​​the body portion (142). The multiple shock absorbing portions (141) may be arranged in a certain order. For example, referring to FIG. 24, the multiple shock absorbing portions (141) may be arranged to be spaced apart from each other by a predetermined interval in the upper, lower, left, and right directions. Here, the predetermined interval may be defined as an interval corresponding to or larger than the size of the shock absorbing portions (141). That is, the shock absorbing portions (141) arranged on the lower side may be located between the shock absorbing portions (141) arranged on the upper side with respect to the X-axis direction. For convenience of explanation, the shock absorbing portions (141) may be defined as a protruding area, and the body portion (142) between the shock absorbing portions (141) may be defined as a concave area. That is, the protruding and concave areas can be arranged alternately based on the same height. Also, that is, the protruding and concave areas can be arranged alternately based on the same Z-axis.

[0198] At this time, the arrangement of the shock absorbing portions (141) of the front absorbing member (140a) and the rear absorbing member (140b) may be different. Specifically, the protruding areas and concave areas of the front absorbing member (140a) and the rear absorbing member (140b) may be arranged opposite to each other. That is, the protruding area of ​​the front absorbing member (140a) may face the concave area of ​​the rear absorbing member (140b), and the concave area of ​​the front absorbing member (140a) may face the protruding area of ​​the rear absorbing member (140b). That is, the respective shock absorbing portions (141) of the front absorbing member (140a) and the rear absorbing member (140b) may not be in contact with each other.

[0199] According to the above-described embodiment of the present invention, when the cell arrays (100) within the pack case (210) are in direct contact with each other, the shock absorbing portion (141) of the front absorbing member (140a) is in contact with the body portion (142) of the rear absorbing member (140b), and the body portion (142) of the front absorbing member (140a) is in contact with the shock absorbing portion (141) of the rear absorbing member (140b), so that the entire area of ​​the absorbing member (140) can absorb the shock. That is, since the shock absorbing area is approximately twice the area of ​​the shock absorbing portion (141), the shock can be absorbed more efficiently.

[0200] The shock absorbing portion (141) may include an absorbing pad (1412) arranged parallel to the body portion (142), and connecting members (1411, 1413) connecting the absorbing pad (1412) and the body portion (142). The absorbing pad (1412) may be a portion that directly contacts the facing cell array (100). The absorbing pad (1412) may directly contact the absorbing member (140) of the facing cell array (100). The absorbing pad (1412) may directly contact the body portion (142) of the facing cell array (100).

[0201] The connecting members (1411, 1413) may be formed to extend from the body portion (142) and be inclined at a predetermined angle from the body portion (142) and the absorbent pad (1412). The connecting members (1411, 1413) may be formed on both sides (left and right sides) of the absorbent pad (1412). According to another embodiment, the connecting members (1411, 1413) may be formed on the upper and lower sides of the absorbent pad (1412).

[0202] The body part (142) may form an opening (145) in a portion that overlaps with the portion where the shock absorbing part (141) is arranged. That is, the portion of the body part (142) that overlaps with the portion where the shock absorbing part (141) is arranged may be omitted. As the shape of the opening (145) is deformed, the shock absorbing part (141) may be deformed.

[0203] The absorbent member (140) may include a material having rigidity and elasticity. For example, the absorbent member (140) may include at least one of materials such as plastic, rubber, silicone, aerogel, metal, and GFRP (glass fiber reinforced plastic). For example, the absorbent member (140) may include plastic.

[0204] According to the above-described embodiment of the present invention, the shape of the absorption pad (1412) may not be temporarily prevented from moving inward due to impact caused by contact between cell arrays (100).

[0205] In another embodiment, the shock absorbing portion (141) may be a portion thicker than the body portion (142). Referring to FIG. 29, the shock absorbing portion (141) may be a separate component that is bonded and fixed on the body portion (142). That is, the body portion (142) may include a material having high rigidity, and the shock absorbing portion (141) may include a material having relatively low rigidity and high elasticity compared to the body portion (142).

[0206] However, the shape and structure of the shock absorbing part (141) are not limited to the above embodiment and can be designed in various ways.

[0207] FIG. 32 is a schematic drawing of a vehicle (V) including a battery pack (10) according to one embodiment of the present invention.

[0208] Referring to FIG. 32, a vehicle (V) according to an embodiment of the present invention may include a battery pack (10) according to an embodiment of the present invention or a cell array (100) and a pack case assembly (200) according to an embodiment of the present invention. The vehicle (V) according to the present invention may be, for example, an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle. The vehicle (V) includes a four-wheel vehicle and a two-wheel vehicle. The vehicle (V) may operate by receiving power from the battery pack (10) or the cell array (100) according to an embodiment of the present invention.

[0209] Although the present invention has been described above with reference to limited embodiments and drawings, the present invention is not limited thereto, and it is obvious that various modifications and variations can be made within the scope of the technical idea of ​​the present invention and the equivalent scope of the claims to be described below by a person skilled in the art to which the present invention pertains.

Claims

1. A cell array comprising a plurality of battery cells; and A pack case assembly comprising a plurality of pack cases arranged to accommodate at least one of the above cell arrays; The above cell array is configured to be inserted in the first direction within the pack case, A battery pack configured such that the above pack cases are connected in a second direction perpendicular to the first direction.

2. In paragraph 1, A battery pack characterized in that the above pack case assembly is configured to be directly mounted to the chassis of a vehicle.

3. In paragraph 1, A battery pack characterized in that the pack case has a square tubular shape with an opening formed on the front or rear surface facing the first direction.

4. In paragraph 3, A battery pack characterized in that the cell array is configured to slide within the pack case through the opening.

5. In paragraph 1, A battery pack characterized in that the pack case is configured to be formed by at least one of extrusion, forging, pressing, and casting methods.

6. In paragraph 1, A battery pack characterized in that the pack cases constituting the pack case assembly are configured to be welded to each other.

7. In paragraph 1, A battery pack characterized in that the pack cases are sequentially combined so that the size of the pack case assembly expands in the second direction.

8. In paragraph 1, A battery pack further comprising at least one venting valve arranged to penetrate at least one venting hole formed on one surface of the pack case.

9. In paragraph 8, A battery pack characterized in that the venting valve is configured to penetrate the lower plate of the case.

10. In paragraph 3, A battery pack further comprising a cap covering the opening and configured to be detachably attached to the pack case.

11. In paragraph 10, Further comprising a busbar assembly electrically connected to the electrode leads of the above battery cell; A battery pack characterized in that the busbar assembly includes a busbar terminal located at the lower portion of the battery cell and configured to be coupled with the electrode lead.

12. In paragraph 11, The above busbar assembly further includes a busbar connector configured to connect the busbar terminals arranged within different pack cases; A battery pack characterized in that the busbar connector is configured to be connected from the outside of the cap by penetrating a hole formed in the cap.

13. In paragraph 1, A battery pack characterized in that it further comprises a side member configured to be directly coupled to the pack case assembly.

14. In paragraph 13, A battery pack characterized in that the above side member is a chassis of an automobile.

15. A vehicle comprising a battery pack according to any one of claims 1 to 14.

16. A cell array comprising a plurality of battery cells; and A pack case assembly comprising a plurality of pack cases arranged to accommodate at least one of the above cell arrays; The above cell array is configured to be inserted in the first direction within the pack case, The above pack cases are configured to be connected in a second direction perpendicular to the first direction, A vehicle, characterized in that the pack case assembly is configured to be directly mounted to the chassis of the vehicle.

17. In paragraph 16, An automobile characterized in that the pack case has a square tubular shape with an opening formed at the front or rear facing the first direction.

18. In paragraph 17, An automobile characterized in that the cell array is configured to slide within the pack case through the opening.

19. In paragraph 1, paragraph 6, An automobile characterized in that the above pack case is configured to be formed by at least one of extrusion, forging, pressing, and casting methods.

20. In paragraph 16, An automobile characterized in that the pack cases constituting the pack case assembly are configured to be welded to each other.

21. In paragraph 16, An automobile characterized in that the pack cases are sequentially combined so that the size of the pack case assembly expands in the second direction.

22. In paragraph 16, An automobile further comprising at least one venting valve arranged to penetrate at least one venting hole formed on one surface of the pack case.

23. In paragraph 22, An automobile characterized in that the venting valve is configured to penetrate the lower plate of the case.

24. In paragraph 17, A vehicle further comprising a cap covering the opening and configured to be detachably attached to the pack case.

25. In paragraph 24, Further comprising a busbar assembly electrically connected to the electrode leads of the above battery cell; An automobile characterized in that the busbar assembly comprises a busbar terminal positioned at the lower portion of the battery cell and configured to be coupled with the electrode lead.

26. In paragraph 25, The above busbar assembly further includes a busbar connector configured to connect the busbar terminals arranged within different pack cases; An automobile characterized in that the busbar connector is configured to be connected from the outside of the cap by penetrating a hole formed in the cap.

27. In paragraph 16, A vehicle characterized in that it further comprises a side member configured to be directly coupled to the pack case assembly.

28. In paragraph 27, A vehicle characterized in that the above side member is a chassis of the vehicle.

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