Patent Description:
The present invention relates to a battery module manufacturing apparatus and a manufacturing method using the same, and more particularly to a battery module manufacturing apparatus including a temperature convertor capable of switching between a heating function and a cooling function, thereby improving production efficiency, and a battery module manufacturing method using the same.

With increasing demand for portable electronic devices, such as a smartphone, a tablet, and a laptop computer, demand for secondary batteries as energy sources thereof has also abruptly increased. Thereamong, a lithium secondary battery, which has high energy density and a long battery lifespan, has been most widely used.

The lithium secondary battery includes an electrode assembly configured such that a positive electrode plate having a positive electrode active material applied thereto and a negative electrode plate having a negative electrode active material applied thereto are disposed in the state in which a separator is interposed therebetween and a battery case in which the electrode assembly is received together with an electrolytic solution in a hermetically sealed state. In general, the lithium secondary battery may be classified as a can-shaped secondary battery having an electrode assembly mounted in a metal can or a pouch-shaped secondary battery having an electrode assembly mounted in a pouch made of an aluminum laminate sheet based on the shape of a sheathing member.

The lithium secondary battery is mounted in a module case in the state in which an electric connection member and a safety member are connected to the lithium secondary battery and is fixed by a reversible or irreversible fixing means, whereby the lithium secondary battery is manufactured as a battery module. A battery module manufacturing process is performed by automated equipment, and generally includes unit processes, such as fixation of battery cells, cooling of a battery module, and end-of-life (EOL) inspection of the manufactured battery module. Since the respective processes are performed while the battery module is moved to respective process positions, there is a problem in that overall configuration of processes is complicated and total production time is long.

In particular, an adhesive for structures used to manufacture the battery module needs about <NUM> hours to completely harden at room temperature. Accordingly, the battery module is manufactured through a high-temperature hardening method using a high-temperature hardening apparatus in order to reduce processing time. In addition, a separate cooling apparatus is used in order to uniformly cool the battery module before EOL inspection, or inspection is performed after the battery module is left for a predetermined time so as to be cooled.

A conventional battery module manufacturing process is performed in a manner in which glue is applied to a module assembly jig, cells are inserted, components are assembled, and high-temperature hardening is performed in a high-temperature hardener for a predetermined time. In this process, however, hardening time is long, and there occurs temperature deviation between the cells. In addition, when the next manufacturing process is completed after high-temperature hardening, a separate cooling process for eliminating the temperature deviation is necessary for EOL inspection. If the separate cooling process is added in order to uniformly cool the battery module, as described above, the manufacturing process time is lengthened, and a congestion section occurs in the overall process, whereby the overall production process is delayed.

Patent Document <NUM> relates to a battery pack manufacturing apparatus that couples a pack case in the state in which battery cells are mounted, specifically an apparatus configured such that, in the state in which a product to be processed is located on a lower jig member, the product is pressed by an upper jig member that is operated by pressure of a press such that the product is processed. The press is installed at an upper end part of a frame of the apparatus, the upper jig member is installed at the frame by a tension spring, a sensing unit configured to detect pressing force from the press is installed on the upper jig member, and the pressure applied by the press is adjusted based on the pressure detected by the sensing unit.

Patent Document <NUM> discloses a battery pack manufacturing method using a receptor configured to receive a plurality of cells, a plate cover configured to close one surface of the receptor, and a mounting bolt configured to mount the cover to an intermediate member, wherein the receptor is provided with battery cell holders, an adhesive is injected into the battery cell holders between outer circumferential surfaces of the battery cells and inner circumferential surfaces of the battery cell holders in order to fix the battery cells in the battery cell holders.

Patent Document <NUM> discloses a battery module manufacturing method of adding a thermosetting and ultraviolet-setting adhesive to an inner surface of a receiving portion having a plurality of hollow structures formed in a module housing, mounting cylindrical battery cells in the receiving portion, applying heat to the adhesive in order to reduce viscosity of the adhesive, and irradiating the adhesive with ultraviolet light in order to finally harden the adhesive such that the cylindrical battery cells are fixed to the module housing.

However, Patent Document <NUM> to Patent Document <NUM>, each of which relates to a battery module manufacturing apparatus or a battery module manufacturing method, do not consider the fact that hardening and cooling processes are constituted as separate processes, whereby the overall process time is increased, and therefore process efficiency is affected.

Therefore, technology related to a battery module manufacturing apparatus capable of switching between a heating function and a cooling function, which is recognized to be an important problem in the present invention, thereby reducing adhesive hardening time necessary to fix battery cells and performing immediate cooling without movement to another process, and therefore it is possible to improve overall process efficiency and to secure productivity, has not yet been proposed.

Further background art is described <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

The present invention has been made in view of the above problems, and it is an object of the present invention to provide a battery module manufacturing apparatus that is capable of switching between a heating function and a cooling function in a single apparatus, is capable of reducing hardening time, and performs no further cooling process, thereby improving production efficiency.

A battery module manufacturing apparatus according to the present invention to accomplish the above object is according to claim <NUM> and includes a pressing jig (<NUM>) and a base jig (<NUM>) located under the pressing jig (<NUM>), wherein the base jig (<NUM>) includes a temperature convertor capable of switching between a heating function and a cooling function.

The temperature convertor includes a thermoelectric device (<NUM>), and the thermoelectric device (<NUM>) may heat or cool a battery module (<NUM>) located at an upper end of the base jig (<NUM>) by changing a direction in which current is supplied.

The thermoelectric device may be a Peltier element.

A thermal pad (<NUM>) may be located at an upper end of the thermoelectric device (<NUM>).

A cooler may be located at a lower end of the thermoelectric device (<NUM>).

The cooler may include a cooling fin (<NUM>).

The cooler may include one or more cooling fans (<NUM>) located at a lower end part of the cooling fin (<NUM>).

A temperature sensor (<NUM>) electrically connected to a controller may be located at the temperature convertor, and the controller may control the temperature of the temperature convertor using received temperature data.

In addition, the present invention provides a battery module manufacturing method according to claim <NUM> which includes (s1) setting a heat transfer plate on a base jig, (s2) disposing a module housing at an upper end of the heat transfer plate, (s3) applying an adhesive to the interior of a battery cell receiving portion of the module housing, (s4) disposing a battery cell in the battery cell receiving portion and assembling components, (s5) heating an upper end surface of the base jig, and (s6) cooling the upper end surface of the base jig.

The battery module manufacturing method may further include preheating the module housing in step (s2).

A direction in which current is supplied to a thermoelectric device located at the base jig may be changed to perform the heating in step (s5) and to perform the cooling in step (s6).

In addition, the present invention provides a battery module produced by the battery module manufacturing method according to the present invention.

In addition, the present invention may provide various combinations of the above solving means.

As is apparent from the above description, in a battery module manufacturing apparatus according to the present invention, it is possible to switch between a heating function and a cooling function in a single apparatus, whereby it is possible to simplify the configuration of a process, to improve overall production efficiency, and to reduce manufacturing cost.

No further cooling process is necessary, whereby it is possible to prevent movement of a battery module or application of impact to the battery module while the battery module is transferred to the cooling process, and therefore it is possible to improve quality of the battery module.

In addition, all numeric ranges include the lowest value, the highest value, and all intermediate values therebetween unless the context clearly indicates otherwise.

Hereinafter, a coating apparatus according to the present invention will be described with reference to the accompanying drawings.

<FIG> is an exploded perspective view of a battery module manufacturing apparatus according to an embodiment of the present invention, <FIG> is a perspective view of a base jig and a pressing jig configured to press a battery module, and <FIG> is a sectional view of the base jig taken along line A-A' of <FIG>.

When describing the battery module manufacturing apparatus according to the embodiment of the present invention with reference to <FIG>, the battery module manufacturing apparatus includes a pressing jig <NUM> and a base jig <NUM>.

When describing the base jig <NUM> in detail first, the base jig <NUM> may include a base jig frame <NUM>, a mounting portion (not shown) configured to allow a battery module <NUM> to be mounted to an upper end surface thereof, and a supporting portion (not shown) configured to support the battery module <NUM> mounted to the mounting portion so as not to move leftwards, rightwards, forwards, and rearwards.

The mounting portion of the base jig <NUM> may form a horizontal plane and may include a thermal pad <NUM> that faces a lower end surface of the battery module <NUM> located at the upper end of the mounting portion, and a thermoelectric device <NUM> may be disposed at a lower end of the thermal pad <NUM>.

The thermal pad <NUM> may efficiently transfer heat.

In the present invention, when ends of two kinds of metals are connected to each other and current flows therethrough, one terminal of the thermoelectric device <NUM> constitutes a low temperature portion configured to perform an endothermic operation and the other terminal of the thermoelectric device constitutes a high temperature portion configured to perform an exothermic operation depending on the direction in which current flows. That is, when the direction in which current flows in the thermoelectric device <NUM> is changed, the low temperature portion and the high temperature portion of the thermoelectric device <NUM> are switched.

The thermoelectric device portion <NUM> includes a thermoelectric element, such as a Peltier element. When ends of two kinds of metals are connected to each other and current flows therethrough, one terminal of the thermoelectric element constitutes a low temperature portion configured to perform an endothermic operation and the other terminal of the thermoelectric element constitutes a high temperature portion configured to perform an exothermic operation depending on the direction in which current flows. At this time, when semiconductors having different electric conduction modes, such as bismuth (Bi) and tellurium (Te), are used instead of the two kinds of metals, it is possible to obtain a Peltier element capable of performing an endothermic operation and an exothermic operation with high efficiency.

When electric power is supplied to the thermoelectric device <NUM>, the endothermic operation or the exothermic operation is performed toward an upper part or a lower part of the thermoelectric device <NUM> depending on the direction in which the electric power is supplied.

First, heating and cooling processes of the base jig <NUM> will be described.

When electric power is supplied, the endothermic operation is performed at the lower part of the thermoelectric device <NUM>, and the exothermic operation is performed at the upper part of the thermoelectric device, the battery module <NUM> abutting the upper part of the thermoelectric device <NUM> is heated. Conversely, when the exothermic operation is performed at the lower part of the thermoelectric device <NUM>, and the endothermic operation is performed at the upper part of the thermoelectric device, the battery module <NUM> abutting the upper part of the thermoelectric device <NUM> is cooled.

When the endothermic operation is performed at the lower part of the thermoelectric device <NUM> and the exothermic operation is performed at the upper part of the thermoelectric device, heat generated from the upper part of the thermoelectric device <NUM> may be effectively transferred to the battery module <NUM> located at the upper end of the thermal pad <NUM> through a wide surface of the thermal pad located at the upper part of the thermoelectric device <NUM>. In addition, the battery module <NUM> located at the upper end of the base jig <NUM> may be heated, battery cells <NUM>, a description of which will follow, in the battery module <NUM> may be effectively adhered to a module housing <NUM>, a description of which will follow. The battery module <NUM> will be described in detail below with reference to <FIG>.

Meanwhile, although not shown in the drawings, an electric power supply unit and a temperature display unit of the thermoelectric device <NUM> may be included, and a controller configured to control the supply of electric power and current direction switching may be included.

When the endothermic operation is performed at the upper part of the thermoelectric device <NUM> and the exothermic operation is performed at the lower part of the thermoelectric device, heat generated from the lower part of the thermoelectric device <NUM> may be dissipated by a heat dissipation means abutting the lower part of the thermoelectric device <NUM>. Here, the heat dissipation means may include a cooling fin <NUM> and a cooling fan <NUM>. The cooling fin <NUM> may be located at a lower end part of the thermoelectric device <NUM>, and may be located so as to correspond to the entirety of the horizontal plane of the mounting portion (not shown) of the base jig <NUM>. In addition, at least one cooling fan <NUM> may be located at a lower end part of the cooling fin <NUM>.

Heat generated at the lower part of the thermoelectric device <NUM> may be transferred to the cooling fin <NUM>, and the heat may be effectively discharged to the outside through the cooling fan <NUM> located at the lower end part of the cooling fin <NUM>.

At the same time, the battery module <NUM> abutting the upper part of the thermoelectric device <NUM> may be cooled, since the endothermic operation is performed at the upper part of the thermoelectric device <NUM>.

Also, in the present invention, the base jig <NUM> may be provided with at least one temperature sensor <NUM>. The temperature sensor <NUM> may be a thermistor. The temperature sensor <NUM> may be located at the mounting portion (not shown) of the base jig <NUM>, on which the battery module <NUM> is disposed, and specifically may be located in the thermal pad <NUM> layer or may be located so as to protrude above the thermal pad <NUM> and may be disposed so as to contact a surface of a heat transfer plate (not shown) disposed at the upper end surface of the mounting portion to mount the battery module <NUM>. The temperature sensor <NUM> may measure the temperature of a contact part between the battery module <NUM> and the mounting portion of the base jig <NUM>, and may transmit the measured temperature to a controller (not shown).

In the present invention, the heat transfer plate is disposed at the upper end surface of the mounting portion so as to support the battery module <NUM> located at the upper end of the mounting portion and to prevent damage to the thermal pad <NUM>, the thermoelectric device <NUM>, and the temperature sensor <NUM> located at the mounting portion. In addition, the heat transfer plate may be an aluminum plate or a heat sink, which is advantageous to smooth heat transfer between the mounting portion of the base jig <NUM> and the battery module <NUM>.

The thermoelectric device <NUM> may be formed by joining two different kinds of metal plates having good electrical conductivity, a P-type semiconductor P configured to conduct electricity by holes, and an N-type semiconductor N configured to conduct electricity by electrons to each other, the semiconductors being disposed between the two kinds of metal plates. When electric power is applied to the thermoelectric device <NUM> through the controller (not shown), the thermoelectric device <NUM> heats or cools the different metal plates depending on the direction in which current of the applied electric power flows.

The base jig <NUM> according to the present invention may further include a controller (not shown). When a heating function or a cooling function is set through the controller, electric power supplied from a power supply unit (not shown) is provided to a driving portion (not shown) of the thermoelectric device <NUM> according to the setting. The driving portion of the thermoelectric device <NUM> supplies the electric power supplied thereto to the thermoelectric device <NUM> to heat or cool the battery module <NUM> located at the mounting portion of the base jig <NUM> according to a control signal of the controller.

In addition, a heating or cooling target temperature of the battery module <NUM> may be preset through the controller (not shown), and the controller may control driving of the thermoelectric device <NUM> based on the temperature sensed by the temperature sensor <NUM>. That is, when the preset temperature is reached, the supply of electric power to the thermoelectric device <NUM> may be interrupted, whereby it is possible to temporarily stop the heating or cooling function.

Next, the pressing jig <NUM> will be described.

In the present invention, the pressing jig <NUM> may be located at an upper part of the base jig <NUM>. In addition, the pressing jig <NUM> and the base jig <NUM> may be spaced apart from each other by a predetermined distance to define a space configured to receive the battery module <NUM>.

The pressing jig <NUM> may include an additional driving portion configured to move the pressing jig in an upward-downward direction (a z-axis direction), and may be moved downwards so as to come into contact with the battery module <NUM> mounted to the base jig <NUM>. The surface of the pressing jig <NUM> that contacts the battery module <NUM> may be brought into face-to-face contact with the entirety of an upper end surface of the battery module <NUM>.

<FIG> is a schematic view of a battery module according to an embodiment of the present invention.

Referring to <FIG>, the battery module <NUM> may include a plurality of battery cells <NUM> and a module housing <NUM> having formed therein a battery cell receiving portion (not shown) configured to receive the plurality of battery cells <NUM>.

Here, each of the battery cells <NUM> may be a cylindrical battery cell, which may include a cylindrical battery can (not shown) and an electrode assembly (not shown) received in the battery can.

Here, the battery can may include a material that exhibits high electrical conductivity. For example, the battery can may include a nickel, aluminum, or copper material. An electrode terminal may be formed at each of an upper part and a lower part of the battery can. Specifically, a first electrode terminal (not shown) may be formed at a circular flat upper surface of an upper end of the battery can, and a second electrode terminal (not shown) may be formed at a circular flat lower surface of a lower end of the battery can (not shown).

In addition, the electrode assembly may be formed so as to have a structure in which a positive electrode and a negative electrode are wound in a jelly-roll shape in the state in which a separator is interposed therebetween. A positive electrode tab may be attached to the positive electrode and may be connected to the first electrode terminal at the upper end of the battery can. A negative electrode tab may be attached to the negative electrode and may be connected to the second electrode terminal at the lower end of the battery can.

In addition, the cylindrical battery cell may be provided at a lower part thereof with a safety element (e.g. a positive temperature coefficient (PTC) element or a TCO), the resistance of which greatly increases to interrupt current when the temperature in the battery cell increases. In addition, the cylindrical battery cell may be provided with a safety vent configured to have a downwardly protruding shape in a normal state and to rupture while protruding so as to exhaust gas when the pressure in the battery increases.

However, various cylindrical battery cells known when the present application was filed may be applied to the battery module <NUM> according to the present invention, in addition to the cylindrical battery cell described above.

The module housing <NUM> may include a plurality of battery cell receiving portions configured to receive the plurality of battery cells <NUM>. Each of the battery cell receiving portions may be formed in tight contact with an outer surface of a corresponding one of the battery cells <NUM> in a horizontal direction so as to wrap the outer surface of the battery cell.

The module housing <NUM> may include an electrically insulative material, specifically a plastic material.

A first current collection plate <NUM> and a second current collection plate <NUM> may be included such that the plurality of battery cells <NUM> received in the battery cell receiving portions of the module housing <NUM> are electrically connected to each other.

Here, the first current collection plate <NUM> may include an electrically conductive material. For example, the electrically conductive material may be copper or aluminum. In addition, the first current collection plate <NUM> may be configured such that a first connection portion (not shown) formed as the result of protrusion of a part of the first current collection plate and the first electrode terminal (not shown) of each of the battery cells <NUM> are electrically connected to each other.

The first current collection plate <NUM> may be loaded at an upper part of the module housing <NUM> such that the first electrode terminals (not shown) of the plurality of battery cells <NUM> are electrically connected thereto. At this time, the first connection portion (not shown) of the first current collection plate <NUM> and the first electrode terminal may be joined to each other by laser welding or resistance welding.

The second current collection plate <NUM> may include an electrically conductive material. For example, the electrically conductive material may be copper or aluminum. In addition, the second current collection plate <NUM> may be configured such that a second connection portion (not shown) formed as the result of protrusion of a part of the second current collection plate and the second electrode terminal (not shown) of each of the battery cells <NUM> are electrically connected to each other.

The second current collection plate <NUM> may be loaded at a lower part of the module housing <NUM> such that the second electrode terminals (not shown) of the plurality of battery cells <NUM> are electrically connected thereto. At this time, the second connection portion (not shown) of the second current collection plate <NUM> and the second electrode terminal (not shown) may be joined to each other by laser welding or resistance welding.

In the present invention, an adhesive may be added to the entirety of an inner surface of the battery cell receiving portion.

For the adhesive, it is preferable to use at least one selected from the group consisting of mono(meth)acrylate and multifunctional (meth)acrylate as an example of an acrylic-based resin, which is a curable resin; however, the present invention is not limited thereto. The mono (meth) acrylate may be at least one selected from the group consisting of alkyl (meth)acrylate, alkylene (meth)acrylate, and acrylic amide, and the multifunctional (meth)acrylate may be at least one selected from the group consisting of alkyl di(meth)acrylate, alkyl tri(meth)acrylate, alkyl tetra(meth)acrylate, polyether (meth)acrylate, silicone di(meth)acrylate, and urethane di(meth)acrylate.

At least one selected from the group consisting of a cresol novolac epoxy resin, a bisphenol A type epoxy resin, a bisphenol A type novolac epoxy resin, a phenol novolac epoxy resin, a tetrafunctional epoxy resin, a biphenyl type epoxy resin, a triphenol methane type epoxy resin, an alkyl modified triphenol methane epoxy resin, a naphthalene type epoxy resin, a dicyclopentadiene type epoxy resin, a dicyclopentadiene modified phenol type epoxy resin, and a urethane modified epoxy resin may be used as an example of an epoxy-based resin, which is the curable resin; however, the present invention is not limited thereto.

The adhesive may further include a thermal initiator. The thermal initiator may be used to initiate polymerization of the adhesive and to harden the adhesive. In addition, the thermal initiator may be a thermal initiator, well known in the art to which the present invention pertains, which is capable of discharging radicals under a specific temperature condition. For example, an initiator, such as a peroxide-based initiator, an azo-based initiator, or a redox-based initiator, may be used.

The adhesive may be applied to the battery cell receiving portions (not shown) of the module housing <NUM>, and the battery cells <NUM> may be received in the battery cell receiving portions. Here, the module housing <NUM> may be preheated to a predetermined temperature.

After the battery cells <NUM> are received in the battery cell receiving portions (not shown) of the module housing <NUM>, heat may be applied to the adhesive. Specifically, heat may be applied to the adhesive by heating of the thermoelectric device <NUM>.

In addition, the pressing jig <NUM> may be moved downwards to press the upper end surface of the battery module <NUM> at a predetermined pressure. As the result of such pressing, a process in which the battery cells <NUM> are adhered to the interiors of the battery cell receiving portions (not shown) of the module housing <NUM>, to which the adhesive has been added, may be efficiently performed.

After the battery cells <NUM> are fixed to the module housing <NUM> by heating through the above high-temperature hardening work, the heating function of the thermoelectric device <NUM> on the battery module <NUM> may be changed to the cooling function under the control of the controller (not shown), whereby it is possible to cool the heated battery module <NUM>.

When the battery module is cooled to a predetermined temperature, a final product of the battery module in the state in which the battery cells <NUM> are stably fixed to the module housing <NUM> may be completed.

It is possible to provide a battery module manufacturing method using the battery module manufacturing apparatus according to the present invention.

The heat transfer plate is disposed at the upper end surface of the mounting portion (not shown) of the base jig <NUM>, the module housing <NUM> is located at the upper end of the heat transfer plate, and the adhesive is applied to the battery cell receiving portions (not shown) of the module housing <NUM>. The plurality of battery cells <NUM> may be inserted into the plurality of battery cell receiving portions, and the first current collection plate <NUM> and the second current collection plate <NUM> are electrically connected to the first electrode terminals (not shown) and the second electrode terminals (not shown) of the plurality of battery cells, respectively. The above work may be performed while the temperature of the thermoelectric device <NUM> is increased. Here, the module housing <NUM> may have already been preheated.

After the battery cells <NUM> are received in the battery cell receiving portions (not shown), a high-temperature hardening step in which the exothermic operation is performed at the upper part of the thermoelectric device <NUM> in order to heat the adhesive applied to the battery cell receiving portions (not shown) such that the adhesive is melted may be performed. The adhesive may be heated at a temperature of <NUM> to <NUM> for <NUM> to <NUM> seconds. After the high-temperature hardening step, a step in which the endothermic operation is performed at the upper part of the thermoelectric device <NUM> in order to cool the module housing may be performed, whereby manufacture of the battery module may be completed.

Claim 1:
A battery module manufacturing apparatus comprising:
a pressing jig (<NUM>); and
a base jig (<NUM>) located under the pressing jig (<NUM>), wherein
the base jig (<NUM>) comprises a temperature convertor capable of switching between a heating function and a cooling function, characterized in that the temperature convertor comprises a thermoelectric device (<NUM>), and
wherein the thermoelectric device (<NUM>) is configured to heat or cool a battery module (<NUM>) located at an upper end of the base jig (<NUM>) by changing a direction in which current is supplied.