Battery pack and method of manufacturing same

Abstract

According to one embodiment of the present invention, provided is a battery pack comprising: at least one battery module; a first case configured to accommodate any one part of the battery module; a second case coupled to the first case and configured to accommodate the other part of the battery module; and a heat-resistant member configured to block thermal energy generated in the battery module from being transferred to the first case, wherein the heat-resistant member is disposed between the inner surface of the first case and the battery module so as to block any one of the first case and the battery module from the other.

Description

Battery pack and method of manufacturing the same

[0001] The technical field of the present invention relates to a battery pack and a method for manufacturing the same.

[0002] Generally, a battery pack consists of one or more battery modules, various components, and a case surrounding them. When such a battery pack is in operation, if a fire occurs in a battery module, flames are emitted from the top of the module. Meanwhile, since the battery pack case is not equipped with a separate area for venting flames and gases to the outside, the heat from the gases and flames caused by the fire is concentrated at the top of the case.

[0003] As such, when heat is concentrated at the top of the case, the temperature of the top of the case gradually rises over time, causing significant damage to the top of the case. In this way, if damage occurs at the top of the case, flames and gases generated from the battery module leak out of the battery pack, which can have an adverse effect on the surrounding environment of the battery pack.

[0004] Therefore, recently, there has been an increasing demand for battery packs equipped with a structure designed to prevent damage to the top of the case even in the event of a fire in the battery module.

[0005] The present invention, conceived in consideration of the aforementioned problems, can provide a battery pack having a structure that prevents damage to the upper part of the case even when a fire occurs in the battery module.

[0006] 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.

[0007] According to one aspect of the present invention for solving the above-described problem, a battery pack may be provided comprising: at least one battery module; a first case configured to accommodate a portion of the battery module; a second case coupled to the first case and configured to accommodate another portion of the battery module; and a heat-resistant member configured to block heat energy generated in the battery module from being transferred to the first case, wherein the heat-resistant member is disposed between the inner surface of the first case and the battery module so as to block either the first case and the battery module from the other.

[0008] In addition, the above-mentioned heat-resistant member may be provided with a battery pack having a heat resistance higher than the fire resistance of the first case.

[0009] In addition, the above heat-resistant member may be provided as a battery pack comprising a mica material.

[0010] Additionally, a battery pack may be provided in which the heat-resistant member includes a first surface defined as a surface facing the inner surface of the first case, and the first surface is positioned to be in close contact with the inner surface of the first case.

[0011] Additionally, a battery pack may be provided in which the heat-resistant member further includes a second surface defined as a surface facing the battery module, which forms a side opposite to the first surface, and at least a portion of the second surface is configured to be exposed to a space enclosed by the second case and the first case.

[0012] In addition, a battery pack may be provided in which the thickness of the heat-resistant member is formed to be smaller than the thickness of the first case.

[0013] Additionally, a battery pack may be provided in which any part of the battery module is defined as the upper part of the battery module and another part of the battery module is defined as the lower part of the battery module, and the heat-resistant member comprises: a first region; a second region having a shape protruding upward from any part of the first region; and a connecting region connecting the first region and the second region to each other, wherein the direction in which the first region faces the second region in a horizontal direction is called the first direction and the direction opposite to the first direction is called the second direction, the end of the connecting region on the first direction side is connected to the end of the second direction side of the second region, and the end of the connecting region on the second direction side is connected to the end of the first direction side of the first region.

[0014] Additionally, a battery pack may be provided in which, when the direction perpendicular to the first direction and the up-down direction is called the third direction, a virtual plane passing through the connection area and perpendicular to the third direction is called the reference plane, and a cross-section obtained by cutting the heat-resistant member with respect to the reference plane is called the reference cross-section, the inclination with respect to the horizontal direction of the end of the second direction side of the connection area is less than or equal to the inclination with respect to the horizontal direction of the upper end of the first area when the reference cross-section is viewed in the third direction.

[0015] Additionally, a battery pack may be provided in which, when the direction perpendicular to the first direction and the up-down direction is called the third direction, a virtual plane passing through the connection area and perpendicular to the third direction is called the reference plane, and a cross-section obtained by cutting the heat-resistant member with respect to the reference plane is called the reference cross-section, the inclination with respect to the horizontal direction of the end of the second direction side of the connection area is less than or equal to the inclination with respect to the horizontal direction of the upper end of the second area when the reference cross-section is viewed in the third direction.

[0016] Additionally, a battery pack may be provided in which a direction perpendicular to the first direction and the up-down direction is called a third direction, a virtual plane passing through the end of the first direction side of the connection area and perpendicular to the third direction is called a first reference plane, and a virtual plane passing through the end of the second direction side of the connection area and perpendicular to the third direction is called a second reference plane, wherein all areas of the end of the first direction side of the connection area lie on the first reference plane and all areas of the end of the second direction side of the connection area lie on the second reference plane.

[0017] Additionally, a battery pack may be provided, wherein the first region comprises: a first-1 region that forms a portion of the first region and is positioned below the upper side of the second region; and a first-2 region that extends in a first direction from the first-1 region and has a shape that protrudes upward with respect to the first-1 region.

[0018] In addition, a battery pack may be provided in which the height of the top of the first and second regions and the height of the top of the second region are formed to be the same as each other.

[0019] In addition, a battery pack may be provided in which the first region, the second region, and the connecting region are each composed of separate members.

[0020] Additionally, a method for manufacturing a battery pack comprising at least one battery module, a first case in which a portion of the battery module is accommodated, a second case in which another portion of the battery module is accommodated, and a heat-resistant member configured to block heat energy generated from the battery module from being transferred to the first case, may be provided, the method comprising: a first preparation step of preparing a first region forming a portion of the heat-resistant member; a second preparation step of preparing a second region forming another portion of the heat-resistant member; a third preparation step of preparing a connecting region forming the remainder of the heat-resistant member; and a connecting step of connecting the first region and the second region through the connecting region to form the heat-resistant member.

[0021] In addition, a method for manufacturing a battery pack may be provided, further comprising a bonding step of bonding the heat-resistant member formed in the connection step to the inner surface of the first case.

[0022] The battery pack according to the present invention has the effect of preventing damage to the upper part of the case even when a fire occurs in the battery module.

[0023] However, the effects obtainable through the present invention are not limited to those described above, and other unmentioned technical effects will be clearly understood by those skilled in the art from the description of the invention below.

[0024] 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.

[0025] FIG. 1 is a drawing showing the first case of a battery pack separated from the second case according to one embodiment of the present invention.

[0026] FIG. 2 is a perspective view of a heat-resistant member according to one embodiment of the present invention.

[0027] Figure 3 is a longitudinal cross-sectional view of a heat-resistant member cut along A-A' of Figure 2.

[0028] FIG. 4 is a drawing showing a battery pack according to one embodiment of the present invention with the first case omitted.

[0029] Figure 5 is a drawing showing the connection area separated from the heat-resistant member of Figure 4.

[0030] FIG. 6 is a flowchart schematically illustrating a method for manufacturing a battery pack according to one embodiment of the present invention.

[0031] Hereinafter, preferred 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, but 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. Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely some of the most preferred embodiments of the present invention and do not represent all of the technical spirit of the present invention; therefore, it should be understood that various equivalents and modifications capable of replacing them may exist at the time of filing this application.

[0032] Additionally, to aid in understanding the invention, the attached drawings are not drawn to actual scale, and the dimensions of some components may be exaggerated. Furthermore, the same reference numerals may be assigned to identical components in different embodiments.

[0033] The statement that two subjects of comparison are 'identical' means that they are 'substantially identical'. Therefore, substantial identity may include deviations considered low in the industry, for example, deviations within 5%. Additionally, the statement that a parameter is uniform in a given area may mean that it is uniform from an average perspective.

[0034] Although terms such as "first," "second," etc., are used to describe various components, it goes without saying that these components are not limited by these terms. These terms are used merely to distinguish one component from another, and unless specifically stated otherwise, the first component may also be the second component.

[0035] Throughout the specification, unless specifically stated otherwise, each component may be singular or plural.

[0036] The fact that any configuration is placed on the "upper (or lower)" of a component or on the "upper (or lower)" of a component may mean not only that any configuration is placed in contact with the upper (or lower) surface of said component, but also that another configuration may be interposed between said component and any configuration placed on (or below) said component.

[0037] In addition, where it is stated that one component is "connected," "combined," or "joined" to another component, it should be understood that while the components may be directly connected or joined to each other, another component may be "interposed" between each component, or each component may be "connected," "combined," or "joined" through another component.

[0038] Throughout the specification, "A and / or B" means A, B, or A and B unless specifically stated otherwise, and "C to D" means C or more and D or less unless specifically stated otherwise.

[0039] Hereinafter, a battery pack (1) according to one embodiment of the present invention will be described with reference to the drawings.

[0040] FIG. 1 is a drawing showing a first case of a battery pack separated from a second case according to an embodiment of the present invention, FIG. 2 is a perspective view of a heat-resistant member according to an embodiment of the present invention, FIG. 3 is a longitudinal cross-sectional view of a heat-resistant member cut along A-A' of FIG. 2, FIG. 4 is a drawing showing a battery pack according to an embodiment of the present invention with the first case omitted, and FIG. 5 is a drawing showing a connection area separated from the heat-resistant member of FIG. 4.

[0041]

[0042] Referring to FIG. 1, a battery pack (1) according to one embodiment of the present invention may be provided in a vehicle and may be a power source that supplies electric energy to the vehicle. The vehicle may be provided, for example, as a Hybrid Electric Vehicle (HEV), a Plug-in Hybrid Electric Vehicle (PHEV), a Battery Electric Vehicle (BEV), etc. Such a battery pack (1) may be placed in the lower part of the vehicle body, for example. Such a battery pack (1) may include a battery module (10), a first case (20), a second case (30), and a heat-resistant member (40).

[0043] The battery module (10) may be a cell stack having a plurality of battery cells. The battery cell may include an electrode assembly, a current collector, a housing, etc. The electrode assembly may be an electrode assembly for a secondary battery including a positive electrode, a negative electrode, and a separator. The battery module (10) may be provided in one or more ways. Such a battery module (10) may be accommodated inside a first case (20) and a second case (30).

[0044] The first case (20) can accommodate the upper portion of the battery module (10) inside. The first case (20) may be named the 'upper case (20)'. This first case (20) may be optionally connected to the second case (30). Between this first case (20) and the second case (30), a sealing gasket, an insulating gasket, etc. may be provided. The second case (30) can accommodate the lower portion of the battery module (10) inside. This second case (30) may be named the 'lower case (30)'. The battery module (10) may be seated in this second case (30).

[0045] Referring to FIG. 2, the heat-resistant member (40) can block thermal energy generated in the battery module (10) from being transferred to the first case (20). For example, if thermal propagation (TP) occurs in the battery module (10), flames may be ejected from the top of the battery module (10), and the heat-resistant member (40) can prevent the flames from coming into direct contact with the first case (20).

[0046] This heat-resistant member (40) may be placed between the battery module (10) and the first case (20). For example, the heat-resistant member (40) may be placed between the outer upper region of the battery module (10) and the inner surface of the first case (20). This heat-resistant member (40) may block either the battery module (10) or the first case (20) from the other.

[0047] The thermal resistance of such a heat-resistant member (40) may be higher than the thermal resistance of the first case (20). Through such a heat-resistant member (40), damage to the first case (20) can be delayed in the event of thermal runaway occurring in the battery module (10). Such a heat-resistant member (40) may include, for example, a mica material. Among such a heat-resistant member (40), the surface facing the inner surface of the first case (20) may be defined as the first surface.

[0048] The first surface may be positioned to be in close contact with the inner surface of the first case (20). For example, all areas of the first surface may be provided to be in contact with the inner surface of the first case (20).

[0049] The side of the heat-resistant member facing the battery module (10) can be defined as a second side. This second side may be the opposite side of the first side. At least a portion of this second side may be configured to be exposed to the space enclosed by the second case (30) and the first case (20). In other words, at least a portion of the second side may be positioned so as to be spaced apart from the outer side of the battery module (10). For example, the entire area of ​​the second side may be spaced apart from the outer side of the battery module (10).

[0050] A certain gap may be formed between this second surface and the battery module (10). Through this gap, vibrations generated in the battery module (10) can be minimized from being transmitted to the heat-resistant member (40). In other words, through this gap, interference between the heat-resistant member (40) and the battery module (10) is minimized, thereby having the advantage of maximizing the durability of the heat-resistant member (40).

[0051] The thickness of the heat-resistant member (40) may be formed to be smaller than the thickness of the first case (20). The thickness of the heat-resistant member (40) may be defined as the distance between the first surface and the second surface. The thickness of the first case (20) may be defined as the distance between the outer surface and the inner surface of the first case (20). For example, the thickness of the heat-resistant member (40) may be formed to be smaller than half the thickness of the first case (20).

[0052] This heat-resistant member (40) may be divided into a plurality of pieces. For example, the heat-resistant member (40) may be a member formed by connecting at least two pieces having different shapes to each other. The plurality of pieces may be manufactured separately and then combined to form a single member. This heat-resistant member (40) may include a first region (41), a second region (42), and a connecting region (43).

[0053] The first region (41) may form one side of the heat-resistant member (40). This first region (41) may include a first-1 region (411) and a first-2 region (412). Among the horizontal directions, the direction in which the first-1 region (411) faces the first-2 region (412) is defined as the first direction (D1), and the direction opposite to the first direction (D1) may be defined as the second direction (D2).

[0054] The first-1 region (411) may form the second direction (D2) side of the first region (41). The first-2 region (412) may have a shape extending in the first direction (D1) from the end of the first direction (D1) side of the first-1 region (411). The vertical height (H) of the top of this first-2 region (412) may be higher than the vertical height (H) of the top of the first-1 region (411).

[0055] Referring to FIG. 3, when a virtual plane passing through the center of the heat-resistant member (40) and perpendicular to the third direction (D3) is called a reference plane, the cross-section formed by cutting the heat-resistant member (40) with respect to the reference plane can be named a reference cross-section. The third direction (D3) can be defined as a direction perpendicular to the vertical direction (H) and the first direction (D1). When this reference cross-section is viewed in the third direction (D3), the first-2 region (412) may extend in the first direction (D1) and upward, and have a shape inclined with respect to the ground. These first-1 region (411) and first-2 region (412) may be formed integrally with each other. However, this is not limited to such examples, and the first-1 region (411) and first-2 region (412) may be composed of separate members that are joined together.

[0056] The second region (42) can form the first direction (D1) side of the heat-resistant member (40). This second region (42) can be connected to the first region (41) through the connecting region (43). The vertical height (H) of the upper part of this second region (42) can be formed to be equal to the vertical height (H) of the upper part of the first-second region (412).

[0057] Referring to FIGS. 4 and 5, the connecting area (43) can connect the first area (41) and the second area (42) to each other in the first direction (D1) and the second direction (D2). This connecting area (43) can be positioned between the first area (41) and the second area (42) with respect to the first direction (D1).

[0058] The second direction (D2) side end of this connecting area (43) and the first direction (D1) side end of the first area (41) can be connected to each other. The second direction (D2) side end of this connecting area (43) and the first direction (D1) side end of the first area (41) can be arranged to face each other.

[0059] When the reference cross-section is viewed from the third direction (D3), the horizontal inclination of the second direction (D2) side end of the connecting area (43) can be formed to be less than or equal to the horizontal inclination of the top of the first area (41). The horizontal inclination may refer to the inclination relative to the ground. For example, the horizontal inclination of the second direction (D2) side end of the connecting area (43) may be 0 (parallel to the ground).

[0060] The first direction (D1) side end of the connecting area (43) and the second direction (D2) side end of the second area (42) can be connected to each other. The first direction (D1) side end of the connecting area (43) and the second direction (D2) side end of the second area (42) can be arranged to face each other.

[0061] When the reference cross-section is viewed from the third direction (D3), the horizontal inclination of the first direction (D1) side end of the connecting area (43) can be formed to be less than or equal to the horizontal inclination of the upper end of the second area (42). For example, the horizontal inclination of the first direction (D1) side end of the connecting area (43) can be 0 (parallel to the ground).

[0062] The first region (41), the second region (42), and the connecting region (43) may each be composed of separate members. However, the concept of the present invention is not limited thereto, and the first region (41), the second region (42), and the connecting region (43) may be formed integrally with each other.

[0063] Hereinafter, with reference to FIG. 6, a method (S10) for manufacturing a battery pack according to an embodiment of the present invention will be described. When describing the method (S10) for manufacturing a battery pack, the description of the battery pack (1) according to an embodiment of the present invention described above will be used.

[0064] FIG. 6 is a flowchart schematically illustrating a method for manufacturing a battery pack according to one embodiment of the present invention.

[0065] Referring to FIG. 6, a method for manufacturing a battery pack (S10) may include a first preparation step (S100), a second preparation step (S200), a third preparation step (S300), a connection step (S400), and a bonding step (S500).

[0066] In the first preparation stage (S100), the first area (41) may be prepared. In the second preparation stage (S200), the second area (42) may be prepared. In the third preparation stage (S300), the connection area (43) may be prepared. These first preparation stage (S100), second preparation stage (S200), and third preparation stage (S300) may each be performed simultaneously or at different times.

[0067] In the connection step (S400), the first region (41) and the second region (42) can be connected to each other through the connection region (43). In this connection step (S400), a heat-resistant member (40) can be formed in which the first region (41), the second region (42), and the connection region (43) are all combined. This connection step (S400) can be performed after the first preparation step (S100), the second preparation step (S200), and the third preparation step (S300) have been performed.

[0068] In the contact step (S500), a heat-resistant member (40) may be in contact with the inner surface of the first case (20). For example, in the contact step (S500), the entire area of ​​the first surface of the heat-resistant member (40) may be placed in contact with the inner surface of the first case (20). This contact step (S500) may be performed after the connection step (S400).

[0069] Although the present invention has been described above 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.

[0070] [Explanation of the symbol]

[0071] 1: Battery pack

[0072] 10: Battery module

[0073] 20: Case 1

[0074] 30: Case 2

[0075] 40: Heat-resistant member

[0076] 41: First Zone

[0077] 411: Area 1-1

[0078] 412: Zones 1-2

[0079] 42: Second Zone

[0080] 43: Connection area

[0081] D1: First direction

[0082] D2: Second direction

[0083] D3: Third direction

[0084] H: Up and down direction

Claims

1. At least one battery module; A first case configured to accommodate a portion of the above-mentioned battery module; A second case coupled to the first case and configured to accommodate another part of the battery module; and It includes a heat-resistant member configured to block thermal energy generated in the battery module from being transferred to the first case, and The above heat-resistant member is, A structure disposed between the inner surface of the first case and the battery module such that one of the first case and the battery module blocks the other. Battery pack.

2. In Paragraph 1, The above heat-resistant member is, Having thermal resistance higher than that of the first case above, Battery pack.

3. In Paragraph 2, The above heat-resistant member is, Including mica material, Battery pack.

4. In Paragraph 1, The above heat-resistant member is, It includes a first surface defined as a surface facing each other with the inner surface of the first case, and The first surface is positioned to be in close contact with the inner surface of the first case. Battery pack.

5. In Paragraph 4, The above heat-resistant member is, It further includes a second surface that forms an opposite side to the first surface and is defined as a surface facing the battery module, and At least a portion of the above-mentioned second surface is, Configured to be exposed in the space surrounded by the second case and the first case, Battery pack.

6. In Paragraph 1, The thickness of the above heat-resistant member is, formed to be smaller than the thickness of the first case above, Battery pack.

7. In Paragraph 1, Any part of the above battery module is defined as the upper part of the above battery module, and The other part of the battery module is defined as the lower part of the battery module, and The above heat-resistant member is, Area 1; A second region having a shape protruding upward with respect to any part of the first region; and It includes a connecting area that connects the first area and the second area, and When the direction in the horizontal direction in which the first region faces the second region is called the first direction, and the direction opposite to the first direction is called the second direction, The first direction side end of the above connection area is connected to the second direction side end of the above second area, and The second direction side end of the above connection area is connected to the first direction side end of the above first area, Battery pack.

8. In Paragraph 7, When the direction perpendicular to the first direction and the up-and-down direction is called the third direction, a virtual plane passing through the connection area and perpendicular to the third direction is called the reference plane, and the cross-section obtained by cutting the heat-resistant member with the reference plane is called the reference cross-section, When the above reference cross-section is viewed in the above third direction, the inclination with respect to the horizontal direction of the second direction side end of the above connection area is, Less than or equal to the slope with respect to the horizontal direction of the top of the first region, Battery pack.

9. In Paragraph 7, When the direction perpendicular to the first direction and the up-and-down direction is called the third direction, a virtual plane passing through the connection area and perpendicular to the third direction is called the reference plane, and the cross-section obtained by cutting the heat-resistant member with the reference plane is called the reference cross-section, When the above reference cross-section is viewed in the above third direction, the inclination with respect to the horizontal direction of the second direction side end of the above connection area is, Less than or equal to the slope with respect to the horizontal direction of the upper part of the second region, Battery pack.

10. In Paragraph 7, When the direction perpendicular to the first direction and the up-down direction is called the third direction, the virtual plane passing through the end of the connection area on the side of the first direction and perpendicular to the third direction is called the first reference plane, and the virtual plane passing through the end of the connection area on the side of the second direction and perpendicular to the third direction is called the second reference plane, All regions of the first direction side end of the above connection region are placed on the first reference plane, and All areas of the second direction side end of the above connection area are placed on the second reference plane, Battery pack.

11. In Paragraph 7, The above-mentioned first region is, A first-1 region forming any part of the first region and positioned below the top of the second region; and A first-2 region extending in a first direction from the first-1 region and having a shape protruding upward with respect to the first-1 region, Battery pack.

12. In Paragraph 11, The height of the upper part of the first and second regions and the height of the upper part of the second region are formed to be the same as each other. Battery pack.

13. In Paragraph 7, The first region, the second region, and the connecting region are each composed of separate members. Battery pack.

14. A method for manufacturing a battery pack comprising at least one battery module, a first case in which a part of the battery module is accommodated, a second case in which another part of the battery module is accommodated, and a heat-resistant member configured to block heat energy generated from the battery module from being transferred to the first case, A first preparation step of preparing a first region that forms a part of the heat-resistant member; A second preparation step for preparing a second region that forms another part of the heat-resistant member; A third preparation step for preparing a connecting region that forms the remaining part of the heat-resistant member; and A connecting step comprising connecting the first region and the second region through the connecting region to form the heat-resistant member, Method for manufacturing a battery pack.

15. In Paragraph 14, A method further comprising a bonding step of bonding the heat-resistant member formed in the connection step to the inner surface of the first case, Method for manufacturing a battery pack.

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