Battery module

Abstract

A battery module is disclosed. The battery module according to one embodiment of the present invention may comprise: an inner frame providing a space therein and including a plastic material; a plurality of battery cells located inside the inner frame; and an outer frame covering the inner frame and including a metal material.

Description

battery module

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

[0002] This application is a priority claim application for Korean Patent Application No. 10-2024-0188958 filed on December 17, 2024, and all contents disclosed in the specification and drawings of said application are incorporated into this application by reference.

[0003] As the demand for portable electronic products such as smartphones, tablet PCs, and smartwatches increases significantly and electric vehicles become increasingly widespread, research on batteries installed in them, particularly secondary batteries capable of repeated charging and discharging, is actively underway.

[0004] Currently commercialized secondary batteries include nickel-cadmium, nickel-hydrogen, nickel-zinc, and lithium secondary batteries. Among these, lithium secondary batteries are gaining attention for their advantages, such as the ability to freely charge and discharge with almost no memory effect compared to nickel-based secondary batteries, a very low self-discharge rate, and high energy density.

[0005] These lithium secondary batteries primarily use lithium-based oxides and carbon materials as the positive and negative active materials, respectively. The lithium secondary battery comprises an electrode assembly in which a positive plate and a negative plate, each coated with the positive and negative active materials, are arranged with a separator in between, and an outer casing, namely a battery case, that seals and houses the electrode assembly together with an electrolyte.

[0006] Generally, lithium secondary batteries can be classified according to the shape of the casing into can-type secondary batteries, in which the electrode assembly is embedded in a metal can, and pouch-type secondary batteries, in which the electrode assembly is embedded in a pouch of aluminum laminate sheet.

[0007] Recently, secondary batteries are widely used for driving or energy storage not only in small devices such as portable electronic devices but also in medium-to-large devices such as electric vehicles and Energy Storage Systems (ESS). A single battery module can be formed by housing multiple such secondary batteries together inside a module case while electrically connected. In this case, each secondary battery included in a single battery module can be referred to as a battery cell. Furthermore, multiple such battery modules can be connected to form a single battery pack.

[0008] However, when a battery pack contains multiple battery modules, and each module contains multiple battery cells, it may be vulnerable to thermal chain reactions between modules or cells. For example, if an event such as thermal runaway occurs within a single battery module, it is necessary to suppress the propagation of this runaway to other battery modules or cells. If the propagation of thermal runaway between modules or cells is not properly suppressed, an event originating in a specific module or cell may trigger a chain reaction of thermal reactions in other modules or cells, potentially causing explosions or fires, or significantly amplifying their scale.

[0009] In particular, if an event such as thermal runaway occurs in a single battery module, gases or flames may be randomly released to the outside. If the release of such gases or flames is not properly controlled, they may be released toward other battery modules, potentially causing a thermal chain reaction in those modules. Specifically, module terminals may be located on the front side of a battery module to provide electrical connections to other battery modules or battery packs, such as module busbars. Therefore, if flames are released toward the front of such a battery module, they can damage the module terminals within the battery pack and cause an electrical short circuit. Furthermore, since other battery modules may be located in front of a specific battery module, if flames are released toward the front of that module, the emitted flames may spread toward other modules, making it easy for fire to spread between battery modules.

[0010] If thermal propagation between battery modules or between battery cells is not properly controlled, a rapid voltage drop in the battery module or battery pack may occur. This can lead to a sudden shutdown of the device equipped with the battery module or battery pack, causing unexpected damage. For example, if a sudden voltage drop in the battery pack occurs while an electric vehicle is in operation, there may not be enough time to move the electric vehicle to a safe location.

[0011] Furthermore, if thermal propagation between battery modules or battery cells is not properly controlled and a fire or explosion occurs suddenly, there is a high possibility of causing casualties to users. For example, if thermal runaway occurs in an electric vehicle and a certain amount of time is not secured before it progresses into a full-scale fire, the occupants may not be able to escape safely.

[0012] Accordingly, the present invention is devised to solve the above-mentioned problems and aims to provide a battery module with improved rigidity to withstand impact or flame, a battery pack including the same, and an automobile, etc.

[0013] Another objective of the present invention may be to provide a structure that can improve energy density by reducing the weight of the battery module.

[0014] Another objective of the present invention is that the electrical safety of the battery module can be improved by the inner frame of the battery module including an electrical insulating material.

[0015] However, the technical problems that the present invention aims to solve are not limited to those described above, and other unmentioned problems will be clearly understood by those skilled in the art from the description of the invention below.

[0016] A battery module according to one embodiment of the present invention for achieving the above-mentioned purpose may include: an inner frame having an internal space and comprising a plastic material; a plurality of battery cells located inside the inner frame; and an outer frame covering the inner frame and comprising a metal material.

[0017] Additionally, the outer frame may have a first opening that exposes the inner frame.

[0018] Additionally, the inner frame may include: a bottom plate located below the plurality of battery cells; and a side plate extending from the bottom plate and covering one side of the plurality of battery cells.

[0019] In addition, the outer frame may be configured to surround the inner frame.

[0020] Additionally, the outer frame may include: a bottom cover located below the bottom plate; a side cover covering the side plate; and a top cover located above the plurality of battery cells.

[0021] In addition, the battery module may further include an insulating plate located between the top cover and the plurality of battery cells.

[0022] In addition, the top cover may have a second opening that exposes the insulating plate.

[0023] In addition, the battery module may further include an end cover that covers the front side of the plurality of battery cells and is coupled to the outer frame.

[0024] In addition, the battery module may further include a welded portion that joins the end cover and the outer frame.

[0025] In addition, a battery pack according to another aspect of the present invention for achieving the above-mentioned purpose includes a battery module according to the present invention.

[0026] In addition, an automobile according to another aspect of the present invention for achieving the above-mentioned purpose includes a battery module according to the present invention.

[0027] According to at least one of the embodiments of the present invention, the battery module can maintain a stable shape even when exposed to shock or flame.

[0028] According to at least one of the embodiments of the present invention, the energy density of the battery module can be improved.

[0029] According to at least one of the embodiments of the present invention, the electrical safety of the battery module can be improved.

[0030] The following drawings attached to this specification illustrate preferred embodiments of the present invention and serve to further enhance understanding of the technical concept of the present invention together with the detailed description of the invention provided below; therefore, the present invention should not be interpreted as being limited only to the matters described in such drawings.

[0031] FIG. 1 is a drawing showing a battery pack according to one embodiment of the present invention.

[0032] Figure 2 is a diagram showing a partial configuration of the battery pack of Figure 1 separated.

[0033] Figure 3 is a diagram showing a partial configuration of the battery pack of Figure 2 separated.

[0034] Figure 4 is a drawing showing the battery module of Figure 3.

[0035] Figure 5 is a diagram showing a partial configuration of the battery module of Figure 3.

[0036] Figure 6 is a diagram showing a partial configuration of the battery module of Figure 5.

[0037] Figure 7 is a drawing showing the combination of the configuration of Figure 6 and the busbar frame assembly.

[0038] Figure 8 is a drawing showing the combination of the configuration of Figure 7 and the inner frame.

[0039] Figure 9 is a drawing showing the configuration of Figure 8 and the combination of the second insulating cover and the end cover.

[0040] FIGS. 10 to 12 are drawings showing the combination of the configuration of FIG. 9 and the outer frame.

[0041] FIG. 13 is a drawing showing a vehicle according to one embodiment of the present invention.

[0042] Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, and should be interpreted in a meaning and concept consistent with the technical spirit of the present invention, based on the principle that the inventor can appropriately define the concept of the terms to best describe his invention.

[0043] Therefore, the embodiments described in this specification and the configurations illustrated in the drawings are merely examples of the present invention and do not represent all aspects of the technical concept of the present invention; thus, it should be understood that various equivalents and modifications that can replace them may exist at the time of filing this application.

[0044] FIG. 1 is a drawing showing a battery pack (1000) according to an embodiment of the present invention. FIG. 2 is a drawing showing a partial configuration of the battery pack (1000) of FIG. 1 separated. FIG. 3 is a drawing showing a partial configuration of the battery pack (1000) of FIG. 2 separated.

[0045] Referring to FIGS. 1 to 3, the case (100) may provide an internal space. The case (100) may include a base plate (110). The base plate (110) may have a rectangular shape. The base plate (110) may have a flat shape. The base plate (110) may form the exterior of the battery pack (1000). The base plate (110) may provide an internal space for the battery pack (1000).

[0046] The case (100) may include a side wall (120). The side wall (120) may be installed, fastened, fixed, joined, or attached to the upper surface of the base plate (110). The side wall (120) may be provided along the perimeter of the base plate (110). For example, the side wall (120) may be composed of four. The side wall (120) may provide an internal space for the battery pack (1000).

[0047] The case (100) may include a pack cover (150). The pack cover (150) may have a square plate shape. The pack cover (150) may have a flat plate shape. The pack cover (150) may form the exterior of the battery pack (1000). The pack cover (150) may cover the internal space of the battery pack (1000). The pack cover (150) may be installed, fastened, fixed, coupled, or attached to the side wall (120).

[0048] A battery pack (1000) according to one embodiment of the present invention may include a partition wall (300). The partition wall (300) may include a first partition wall (310) and a second partition wall (320). The partition wall (300) may be provided in multiple numbers. The partition wall (300) may be installed, fastened, fixed, coupled, or attached to the upper surface of a base plate (110). The partition wall (300) may partition the internal space of the battery pack (1000).

[0049] The first partition wall (310) may be extended along the front-rear direction or the X-axis direction. The first partition wall (310) may be provided in multiple numbers. The multiple first partition walls (310) may be arranged along the left-right direction or the Y-axis direction.

[0050] The second partition wall (320) may be extended along the left-right direction or the Y-axis direction. A plurality of first partition walls (310) may be arranged on each side of the second partition wall (320).

[0051] The battery module (200) may be placed inside the case (100). The battery module (200) may be installed, fastened, fixed, coupled, or attached to the upper surface of the base plate (110). The battery module (200) may be provided in multiple numbers. For example, the battery module (200) may be composed of six units. The battery module (200) may be located in the space partitioned by the partition wall (300).

[0052] A venting device (500) may be installed on a side wall (120). For example, the venting device (500) may be installed on the right side wall (120). For example, the venting device (500) may be a gas valve. The venting device (500) may open to discharge gas when the pressure inside the case (100) increases. Additionally, the venting device (500) may block external air from entering the case (100). Multiple venting devices (500) may be provided.

[0053] FIG. 4 is a drawing showing the battery module (200) of FIG. 3. FIG. 5 is a drawing showing a partial configuration of the battery module (200) of FIG. 3 separated.

[0054] Referring to FIGS. 4 and 5, the battery module (200) may have a rectangular shape. An outer frame (290) may form the exterior of the battery module (200). An inner frame (210) may form the exterior of the battery module (200). An insulating plate (260) may form the exterior of the battery module (200).

[0055] The outer frame (290) may include a first opening (290a). The first opening (290a) may expose the inner frame (210). The outer frame (290) may include a second opening (290b). The second opening (290b) may expose the insulating plate (260).

[0056] The end cover (240) can form the exterior of the battery module (200). The end cover (240) may be provided as a pair. The end cover (240) may include a front end cover (240) and a rear end cover (240). The front end cover (240) may expose the power terminal (231).

[0057] An insulating cover (270) can form the exterior of a battery module (200). An insulating cover (270) may be provided in pairs. An insulating cover (270) may include a front insulating cover (270) and a rear insulating cover (270). The front insulating cover (270) may be positioned between a power terminal (231) and a front end cover (240). The front insulating cover (270) may electrically insulate the power terminal (231) and the front end cover (240).

[0058] FIG. 6 is a drawing showing a part of the configuration of the battery module (200) of FIG. 5.

[0059] Referring to FIGS. 4 through 6, a battery cell (220) may be accommodated inside an outer frame (290). A battery cell (220) may be accommodated inside an inner frame (210). A plurality of battery cells (220) may be provided. A battery cell (220) may refer to a secondary battery. In particular, a battery cell (220) may be a pouch-type secondary battery. However, the shape of the battery cell (220) is not limited to a pouch shape and may have various shapes such as a cylindrical shape or a rectangular shape.

[0060] A plurality of battery cells (220) may be stacked along the left-right direction or the Y-axis direction. A battery cell (220) may include a storage portion (221) having an electrode assembly, a first sealing portion (222) protruding toward the front and rear sides of the storage portion (221), and a second sealing portion (223) protruding toward the upper side of the storage portion (221). Additionally, a battery cell (220) may include electrode leads (224) protruding toward the front and rear sides of the first sealing portion (222), respectively. Each battery cell (220) may be extended along the front-rear direction or the X-axis direction. The electrode leads (224) may protrude toward the front and rear of each battery cell (220).

[0061] A pad (250) may be placed between multiple battery cells (220). The pad (250) may be placed between at least some of the battery cells (220) and / or on the outer edge of the stack. For example, the pad (250) may be configured to be placed between every two battery cells (220) stacked in the left-right direction.

[0062] These pads (250) may be provided with an elastic material to absorb swelling of the battery cell (220). For example, the pads (250) may be made of a foam material such as polyurethane. Alternatively, the pads (250) may be provided with a material capable of blocking heat or flames. For example, the pads (250) may be provided with an insulating or fireproof material such as silicone or mica.

[0063] FIG. 7 is a drawing showing the combination of the configuration of FIG. 6 and the busbar frame assembly (230). FIG. 8 is a drawing showing the combination of the configuration of FIG. 7 and the inner frame (210).

[0064] Referring to FIGS. 4 through 8, a front busbar frame assembly (230) may be provided in front of a plurality of battery cells (220). The front busbar frame assembly (230) may be electrically connected to the front side electrode leads (224) of the plurality of battery cells (220). The front busbar frame assembly (230) may include a power terminal (231).

[0065] A rear busbar frame assembly (230) may be provided at the rear of a plurality of battery cells (220). The rear busbar frame assembly (230) may be electrically connected to the rear side electrode leads (224) of the plurality of battery cells (220).

[0066] The inner frame (210) may include a bottom plate (211). The inner frame (210) may include a side plate (212). The side plate (212) may be provided as a pair. The side plate (212) may extend from the bottom plate (211). The inner frame (210) may be formed integrally. The inner frame (210) may also be referred to as a U-frame (210). The inner frame (210) may form the exterior of the battery module (200). The inner frame (210) may include a plastic material. The inner frame (210) may have electrical insulation properties. The inner frame (210) may provide space inside. The inner frame (210) may accommodate a plurality of battery cells (220). A plurality of battery cells (220) may be accommodated in the inner frame (210).

[0067] A bottom plate (211) may be positioned below a plurality of battery cells (220). The bottom plate (211) may cover the lower surface of the plurality of battery cells (220). A side plate (212) may cover one side of the plurality of battery cells (220). A pair of side plates (212) may cover both sides of the plurality of battery cells (220).

[0068] A heat transfer member (280) may be disposed between a bottom plate (211) and a plurality of battery cells (220). The heat transfer member (280) may include a material with high thermal conductivity. For example, the heat transfer member (280) may be a resin with high thermal conductivity. The heat transfer member (280) may be in contact with the upper surface of the bottom plate (211). The heat transfer member (280) may be in contact with the lower surface of the plurality of battery cells (220). The heat transfer member (280) may attach the plurality of battery cells (220) to the bottom plate (211).

[0069] FIG. 9 is a drawing showing the configuration of FIG. 8 and the combination of the insulating cover (270) and the end cover (240).

[0070] Referring to FIGS. 4 through 9, an insulating plate (260) may be positioned over a plurality of battery cells (220). The insulating plate (260) may cover the upper surface of the plurality of battery cells (220). The insulating plate (260) may have a rectangular shape. The insulating plate (260) may be composed of a sheet having a thin thickness. The insulating plate (260) may have electrical insulation properties. For example, the insulating plate (260) may include a plastic material.

[0071] The end covers (240) may be provided as a pair. The end covers (240) may have a rectangular shape. The end covers (240) may include a metal material. The front end cover (240) may be located in front of the front insulation cover (270). The front end cover (240) may cover the front insulation cover (270). The front end cover (240) may cover the front side of a plurality of battery cells (220). The rear end cover (240) may be located behind the rear insulation cover (270). The rear end cover (240) may cover the rear insulation cover (270). The rear end cover (240) may cover the rear side of a plurality of battery cells (220).

[0072] The insulating covers (270) may be provided in pairs. The insulating covers (270) may have a rectangular shape. The front insulating cover (270) may be positioned between the front end cover (240) and the front busbar frame assembly (230). The front insulating cover (270) may electrically insulate the front busbar frame assembly (230) and the front end cover (240). The rear insulating cover (270) may be positioned between the rear end cover (240) and the rear busbar frame assembly (230). The rear insulating cover (270) may electrically insulate the rear busbar frame assembly (230) and the rear end cover (240).

[0073] FIGS. 10 to 12 are drawings showing the combination of the configuration of FIG. 9 and the outer frame (290).

[0074] Referring to FIGS. 10 through 12, the outer frame (290) can cover the inner frame (210). The outer frame (290) can be configured to wrap around the inner frame (210). The outer frame (290) may include a metal material. The outer frame (290) may be formed by bending or folding a single plate. The outer frame (290) may be welded after being bent or folded. The top cover (293) and the side cover (292) of the outer frame (290) may be joined by welding. A second weld (W2) may join the top cover (293) and the side cover (292).

[0075] The battery module (200) may have improved electrical safety by having an inner frame (210) and an outer frame (290) having electrical insulation. The battery module (200) may have improved rigidity by having an inner frame (210) and an outer frame (290) including a metal material.

[0076] The outer frame (290) may include a bottom cover (291). The bottom cover (291) may be located below the bottom plate (211) of the inner frame (210). The bottom cover (291) may cover the bottom plate (211).

[0077] The outer frame (290) may include a side cover (292). The side cover (292) may be provided as a pair. A pair of side covers (292) may extend from a bottom cover (291). The side cover (292) may be located on the outside of the side plate (212) of the inner frame (210). The side cover (292) may cover the side plate (212). The inner frame (210) may be positioned between a pair of side covers (292).

[0078] The outer frame (290) may include a top cover (293). The top cover (293) may be positioned on top of an insulating plate (260). The insulating plate (260) may be positioned between the top cover (293) and a plurality of battery cells (220). The insulating plate (260) may electrically insulate the top cover (293) and the plurality of battery cells (220).

[0079] The outer frame (290) may include a first opening (290a). The first opening (290a) may expose the inner frame (210). The first opening (290a) may be provided in multiple numbers. The first opening (290a) may be provided in the side cover (292). The first opening (290a) of the side cover (292) may expose the side plate (212). The first opening (290a) may be provided in the bottom cover (291). The first opening (290a) of the bottom cover (291) may expose the bottom plate (211). By providing the first opening (290a) in the outer frame (290), the weight of the battery module (200) can be reduced and the energy density can be increased.

[0080] The outer frame (290) may include a second opening (290b). The second opening (290b) may expose an insulating plate (260). The second opening (290b) may be provided in multiple numbers. The second opening (290b) may be provided in the top cover (293).

[0081] The outer frame (290) can reduce the weight of the battery module (200) and increase the energy density by having a second opening (290b).

[0082] The end cover (240) may be fastened, attached, fixed, or joined to the outer frame (290). The end cover (240) may be made of a metal material, and the end cover (240) may be joined to the outer frame (290) by welding. A first weld (W1) may join the end cover (240) and the outer frame (290).

[0083] The battery pack (1000) according to the present invention may further include various other components in addition to the battery module (200), such as a BMS, a busbar, a relay, a current sensor, etc., and various other components of a battery pack known at the time of filing the present invention.

[0084] FIG. 13 is a drawing showing a vehicle (V) according to one embodiment of the present invention.

[0085] Referring to FIG. 13, the vehicle (V) according to the present invention may include a battery module (200) of the present invention. The vehicle (V) according to the present invention may include a battery pack (1000) of the present invention.

[0086] The battery module (200) or battery pack (1000) according to the present invention may be applied to a vehicle such as an electric vehicle or a hybrid vehicle. The vehicle (V) according to the present invention may further include various other components included in the vehicle in addition to the battery module (200) or battery pack (1000). For example, the vehicle (V) according to the present invention may further include a vehicle body, a motor, an electronic control unit (ECU), and other control devices.

[0087] As described above, although the present invention has been explained by limited embodiments and drawings, the present invention is not limited thereto, and it is obvious that various modifications and variations are possible within the scope of the technical spirit of the present invention and the equivalent scope of the claims described below by those skilled in the art to which the present invention belongs.

Claims

1. An inner frame that provides internal space and includes plastic material; A plurality of battery cells located inside the inner frame; and, A battery module comprising an outer frame that covers the inner frame and includes a metal material.

2. In Paragraph 1, The above outer frame is, A battery module having a first opening that exposes the inner frame.

3. In Paragraph 1, The inner frame above is: A bottom plate located below the plurality of battery cells above; and, A battery module comprising a side plate extending from the bottom plate and covering one side of the plurality of battery cells.

4. In Paragraph 3, The above outer frame is, A battery module configured to surround the inner frame.

5. In Paragraph 3, The above outer frame is: A bottom cover located below the above bottom plate; A side cover covering the above side plate; and, A battery module including a top cover positioned on top of the plurality of battery cells.

6. In Paragraph 5, A battery module further comprising an insulating plate located between the top cover and the plurality of battery cells.

7. In Paragraph 6, The above top cover is, A battery module having a second opening that exposes the insulating plate.

8. In Paragraph 1, A battery module further comprising an end cover that covers the front side of the plurality of battery cells and is coupled to the outer frame.

9. In Paragraph 8, A battery module further comprising a welded portion that joins the end cover and the outer frame.

10. A battery pack comprising a battery module according to any one of claims 1 to 9.

11. An automobile comprising a battery module according to any one of claims 1 to 9.

Images