Patent Description:
Conventionally, in the case of manufacturing a long module by disposing a plurality of sub-modules in which a cell stack and a busbar frame are coupled side by side in a longitudinal direction, each sub-module has been manufactured individually.

That is, after manufacturing one sub-module, another sub-module is manufactured separately. Thereafter, individually manufactured sub-modules are assemblied and welded together side by side in a longitudinal direction and disposed inside a housing.

However, in accordance with such a conventional process, each sub-module is manufactured to have a different structure. Therefore, the overall process of manufacturing a battery module composed of a plurality of sub-modules has been complicated. <CIT> discloses an energy storage apparatus comprising a plurality of energy storage devices stacked in a first direction and coupled to each other by a connecting member, that may be decoupled, and an intermediate member. The disclosed configuration facilitates exchange of some of the energy storage devices without the need to exchange the entire battery module. Specifically, rectangular parts are connected to each other using a concavo-convex fitting engagement. <CIT> discloses a battery module comprising a cell stack that includes a plurality of cells stacked in a first direction and a coupling part. Specifically, the coupling part is configured to be coupled to the coupling part of an adjacent battery module. The coupling part may include fastening parts at a first and at a second wall. A guide groove, that may be disposed between the fastening part and a tube receiving opening, may be configured in a geometry to receive guide pins of a second module housing. <CIT> discloses a battery pack comprising a plurality of individual cell containers clamped together in a way that a small ventilation gap is maintained for the sake of cooling. Specifically, interlocks are disclosed that contain at least one set of complementary shaped (e.g., male and female) projections on juxtaposed walls of adjacent containers.

Present disclosure provides a simplified process of manufacturing a battery module including a plurality of same sub-modules.

Present disclosure provides a battery module in which a central wall is connected to a side cover to have improved mechanical rigidity.

Present disclosure provides a battery module capable of preventing heat from propagating to adjacent sub-modules by coupling a sub-module and a central wall.

According to the present disclosure, a battery module comprises a battery module including: a first sub-module and a second sub-module respectively including a cell stack in which a plurality of battery cells are stacked; and a central wall disposed between the first sub-module and the second sub-module, wherein the central wall includes a first central wall facing the first sub-module and a second central wall facing the second sub-module, wherein the first central wall has a rotationary symmetrical shape of the second central wall around a first axis.

In another embodiment of the present disclosure, the first central wall may be coupled to the first sub-module, and the second central wall may be coupled to the second sub-module.

In still another embodiment of the present disclosure, the first sub-module and the second sub-module may have the same structure.

In yet another embodiment of the present disclosure, the first central wall and the second central wall may have the same structure.

In one embodiment of the present disclosure, the battery module may further include a side cover protecting the first sub-module, and the central wall may be coupled to the side cover.

In another embodiment of the present disclosure, the central wall may include a first fastening groove, and the central wall may be coupled to the side cover through a fastening member and the first fastening groove.

In another embodiment of the present disclosure, the battery module may further include an upper cover covering upper portions of the first sub-module and the second sub-module; and a lower cover covering lower portions of the first sub-module and the second sub-module, wherein the central wall may be coupled to the upper cover and the lower cover.

In yet another embodiment of the present disclosure, the central wall may include a second fastening groove, and the central wall may be coupled to the upper cover and the lower cover through a fastening member and the second fastening groove.

The central wall includes a guide groove and a guide protrusion, which may be formed on one surface thereof, and which are disposed to face each other.

The guide groove and the guide protrusion are disposed to be rotationally symmetrical with respect to a centerline passing through a center of the central wall. In addition, the guide groove of the first central wall and the guide groove of the second central wall are disposed to be rotationally symmetrical around the first axis.

The guide groove of the first central wall is in contact with the guide protrusion of the second central wall, and the guide protrusion of the first central wall is in contact with the guide groove of the second central wall.

In another embodiment of the present disclosure, the central wall may include a plurality of groove portions on one surface thereof.

The plurality of groove portions may expand inwardly from an outer surface of the central wall to an inner side of the center wall.

In a further embodiment of the present disclosure, the plurality of groove portions of the first central wall may extend in a first direction and have depth in a second direction perpendicular to the first direction and be formed in a direction, from the first central wall toward the first sub-module, and the plurality of groove portions of the second central wall may extend in the first direction and have depth in the second direction and be formed in a direction, from the second central wall toward the second sub-module.

<FIG> is an exploded perspective view of a battery module according to one embodiment of the present disclosure. <FIG> is a perspective view of a sub-module according to an embodiment of the present disclosure. <FIG> is an exploded perspective view of the sub-module illustrated in <FIG>.

Referring to <FIG>, a battery module <NUM> of the present disclosure may include a sub-module <NUM> including a central wall <NUM>, and an upper cover <NUM> and a lower cover <NUM> covering the sub-module <NUM>.

The sub-module <NUM> may include a first sub-module <NUM> and a second sub-module <NUM>, and the first submodule <NUM> and the second submodule <NUM> may be disposed to face each other with the central wall <NUM> interposed therebetween. The first sub-module <NUM> and the second sub-module <NUM> may be formed to have the same structure. That is, the first sub-module <NUM> and the second sub-module <NUM> may include the same components (e.g., a cell assembly or a protective cover), and may be manufactured through the same manufacturing process. For example, the second sub-module <NUM> may be in a state in which the first sub-module <NUM> is rotated by <NUM>° around a first direction (Z-direction), as an axis. That is, the first sub-module <NUM> and the second sub-module <NUM> may be disposed to be rotationally symmetrical around a first axis (Z-axis). The first sub-module <NUM> and the second sub-module <NUM> may be disposed to face each other in a second direction (X-direction), perpendicular to the first direction (Z-direction).

The first sub-module <NUM> may include a first central wall <NUM> and the second sub-module <NUM> may include a second central wall <NUM>. The first central wall <NUM> and the second central wall <NUM> may be disposed between the first sub-module <NUM> and the second sub-module <NUM>. The central wall <NUM> may block heat propagation between adjacent sub-modules <NUM>.

The central wall <NUM> may include the first central wall <NUM> and the second central wall <NUM>. The first central wall <NUM> and the second central wall <NUM> may be formed to have the same structure. That is, the first central wall <NUM> and the second central wall <NUM> may include the same components, and may be manufactured through the same manufacturing process. For example, a plurality of grooves may be formed on one surface of the first central wall <NUM> and the second central wall <NUM> in the same manner. Like the first and second sub-modules <NUM> and <NUM>, the second central wall <NUM> may be in a state in which the first central wall <NUM> is rotated by <NUM>° around the first direction (Z-direction), as an axis. That is, the first central wall <NUM> and the second central wall <NUM> may be disposed to be rotationally symmetrical around the first axis (Z-axis).

The battery module <NUM> may include an upper cover <NUM> disposed above the sub-module <NUM> and a lower cover <NUM> disposed below the sub-module <NUM>. For example, the upper cover <NUM> may be disposed to cover upper surfaces of the first and second sub-modules <NUM> and <NUM>, and the lower cover <NUM> may be disposed to cover lower surfaces of the first and secondsub-modules <NUM> and <NUM>.

The battery module <NUM> may include a housing covering the first and second sub-modules <NUM> and <NUM>. For example, the housing may protect all of the upper portions, lower portions, and side surfaces of the first and second sub-modules <NUM> and <NUM>. Although only an upper cover <NUM> and a lower cover <NUM> are illustrated in <FIG>, the housing may additionally include a side cover to cover the first and second sub-modules <NUM> and <NUM>.

The upper cover <NUM> may include an opening <NUM>. As shown in <FIG>, a sensing terminal <NUM> may be disposed on an outer surface of the upper cover <NUM> due to the opening <NUM>. Therefore, even if the upper cover <NUM> covers the upper portions of the first and second sub-modules <NUM> and <NUM>, the sensing terminal <NUM> may be exposed to an upper side thereof (e.g., in the Z-direction) through the opening <NUM> to be connected to an external circuit.

A heat conducting member may be disposed between the lower cover <NUM> and the first and secondsub-modules <NUM> and <NUM>. One surface of the heat conducting member may contact the sub-module <NUM> and the other surface may contact the lower cover <NUM>. The heat conducting member may include a thermal adhesive.

A heat sink <NUM> may be disposed on the lower cover <NUM>. A cooling passage may be formed in the heat sink <NUM>. For example, one heat sink <NUM> may be formed to cover all of the first and second sub-modules <NUM> and <NUM>. However, a structure of the heat sink <NUM> is not limited thereto. For example, a plurality of heat sinks <NUM> may be provided and configured to respectively correspond to the first and second sub-modules <NUM> and <NUM>.

Referring to <FIG> and <FIG>, the sub-module <NUM> may include a cell assembly <NUM> in which a plurality of battery cells <NUM> are stacked in a third direction (Y-direction), and a protective cover <NUM> protecting the cell assembly <NUM> and a central wall <NUM>. The protective cover <NUM> may protect the plurality of battery cells <NUM> from external impacts.

The cell assembly <NUM> may include a cell stack <NUM> including battery cells <NUM> stacked in a third direction (Y-direction), a busbar assembly <NUM> electrically connected to the cell stack <NUM>, and an insulating cover <NUM> coupled to the busbar assembly <NUM>.

The cell stack <NUM> may include one or more battery cells <NUM>. The plurality of battery cells <NUM> included in the cell stack <NUM> may be pouch-type battery cells <NUM>. The battery cell <NUM> may convert chemical energy into electrical energy to supply power to an external circuit or receive power from the outside to convert electrical energy into chemical energy and store the same therein. However, the battery cell <NUM> is not limited to a pouch-type battery cell. For example, the type of battery cell <NUM> may be a prismatic battery cell or a cylindrical battery cell.

The busbar assembly <NUM> may electrically connect the battery cells <NUM> accommodated in the cell assembly <NUM>, and may include a terminal unit <NUM> connected externally. For example, a plurality of busbar assemblies <NUM> may be disposed to be connected to the cell stack <NUM>, and may be provided on both one side surface and the other side surface of the cell stack <NUM>, facing each other. The busbar assembly <NUM> may be disposed on one side surface of the cell stack <NUM>, and the terminal unit <NUM> may be connected to one side surface of an upper plate member <NUM>. The terminal unit <NUM> may include a positive electrode terminal and a negative electrode terminal, and may be disposed to be spaced apart from each other.

The cell assembly <NUM> may include an insulating cover <NUM> coupled to the busbar assembly <NUM>. The insulating cover <NUM> may be connected to the busbar assembly <NUM> and may block electrical connection between the busbar assembly <NUM> and an end cover <NUM>.

The sub-module <NUM> may be connected to the cell assembly <NUM>, and may include an upper plate member <NUM> disposed above the cell assembly <NUM>. A sensing module <NUM> may be disposed on the upper plate member <NUM>.

A sensing terminal <NUM> may be disposed on one side of the upper plate member <NUM> disposed on the central wall <NUM>, and a terminal unit <NUM> may be connected to the other side of the upper plate member <NUM> on which the central wall <NUM> is not disposed.

The sensing module <NUM> may sense electrical and thermal states of the battery cells <NUM> included in the cell assembly <NUM>. The sensing module <NUM> may be disposed above the cell assembly <NUM>, and may be connected to a plurality of battery cells <NUM>.

The sensing module <NUM> may include a sensing terminal <NUM> and a sensing circuit <NUM>.

The sensing circuit <NUM> forms a circuit for sensing electrical and thermal states of the plurality of battery cells <NUM>. For example, the sensing circuit <NUM> may be connected to the busbar assembly <NUM>, and electrically connected to the battery cells <NUM>.

The sensing terminal <NUM> may be connected to the sensing circuit <NUM> and may be connected externally. For example, in the battery module <NUM>, the sensing terminal <NUM> may be connected to the upper cover <NUM>. The sensing terminal <NUM> may be disposed on the other side surface of the upper plate member <NUM> facing one side surface of the upper plate member <NUM> to which the terminal unit <NUM> is connected.

The sub-module <NUM> may include a protective cover <NUM> coupled to the cell assembly <NUM>.

The protective cover <NUM> may include a plurality of end covers <NUM> and a plurality of side covers <NUM> covering at least one side of the cell assembly <NUM>. A lower portion of the cell assembly <NUM> may directly contact a heat sink <NUM> without being covered by the protective cover <NUM>. Accordingly, the cell assembly <NUM> directly contacts the heat sink <NUM> (shown in <FIG>), so that the cooling efficiency of the battery module may be improved.

The end cover <NUM> may be disposed on a side on which the busbar assembly <NUM> is disposed in the sub-module <NUM>, to cover the sub module <NUM>. A plurality of end covers <NUM> may be provided, may be disposed on both sides thereof, and may be connected to the insulating cover <NUM>. For example, an end cover <NUM>, the insulating cover <NUM>, the busbar assembly <NUM>, and the cell stack <NUM> may be sequentially disposed on one side surface of the sub-module <NUM>. That is, the end cover <NUM> may be disposed on both ends of the sub-module <NUM>, and may protect the cell assembly <NUM> from external impacts or the external environment.

The side cover <NUM> may protect a side surface of the cell assembly <NUM>. For example, the side cover <NUM> may be disposed on a side surface of the cell assembly <NUM>, and may be disposed to face a cell body unit of the stacked battery cells <NUM>.

The sub-module <NUM> may include a central wall <NUM> coupled to the cell assembly <NUM>.

The central wall <NUM> may be disposed on a side of the sub-module <NUM> on which the sensing module <NUM> is disposed, to cover the sub module <NUM>. For example, the central wall <NUM> may be provided on only one side of the sub-module, and may protect the cell assembly <NUM>.

The central wall <NUM> may be coupled to the side cover <NUM>. For example, the fastening member <NUM> may couple the central wall <NUM> and the side cover <NUM>. Each of the central wall <NUM> and the side cover <NUM> may include a first fastening groove <NUM> corresponding to the fastening member <NUM>. A plurality of first fastening grooves <NUM> may be provided. The central wall <NUM> and the side cover <NUM> may be fixed by the fastening member(s) <NUM>, and thus mechanical rigidity of the sub-module <NUM> may be improved, and structural stability may be obtained.

In the case of a conventional sub-module, a side cover was not fixed in a process of manufacturing the sub-module, and accordingly, the side cover was fixed and used by applying force from the outside. According to the battery module <NUM> of the embodiments of the present disclosure, since the side cover <NUM> and the central wall <NUM> are coupled so that the side cover <NUM> may be fixed, manufacturing process may be simplified.

In addition, in the case of a conventional battery module, the sub-modules included in the battery module have different structures, so that each of the sub-modules had to be individually manufactured. However, according to one embodiment of battery module <NUM>, the same sub-module <NUM> may be repeatedly manufactured and connected. In addition, according to a central wall <NUM> to be described later, the central wall <NUM> having the same structure may be repeatedly manufactured and coupled to the sub-module <NUM>. Accordingly, the battery module <NUM> may be produced by connecting the sub-module <NUM> connected to the central wall <NUM>, and a manufacturing process of the battery module <NUM> may be simplified.

The central wall <NUM> may perform a function of blocking heat propagation between adjacent sub-modules <NUM>. For example, heat generated in sub-module <NUM> may be prevented from propagating to adjacent sub-modules <NUM>. For example, the central wall <NUM> may be formed of a member having low thermal conductivity. The flame retardant material (such as flame retardant plastic), ceramic coated metal, mica coated metal or flame retardant polymer coated metal can be used to form the central wall <NUM>, but the present disclosure is not limited thereto. By disposing the central wall <NUM> having low thermal conductivity with the adjacent sub-modules <NUM> interposed therebetween, it is possible to reduce or prevent the heat emitted from the sub-modules <NUM> from being conducted to the adjacent sub-modules <NUM>. In addition, as will be described later, a groove portion may be formed in the central wall <NUM>, and thus a space may be formed inside the central wall <NUM>. Accordingly, the internal space of the central wall <NUM> may perform a heat insulating function of blocking heat propagation.

<FIG> is an exploded perspective view of a central wall according to an embodiment of the present disclosure. <FIG> is a perspective view of the central wall illustrated in <FIG>. <FIG> is a plan view of the central wall shown in <FIG>. <FIG> is an exploded perspective view of a central wall according to another embodiment of the present disclosure. <FIG> is a perspective view illustrating the central wall illustrated in <FIG>. <FIG> is a plan view of the central wall illustrated in <FIG>.

Referring to <FIG>, the central wall <NUM> according to embodiments of the present disclosure may be formed to have a length in a third direction (Y-direction). In addition, the central wall 500a (shown in <FIG>) may include a plurality of groove portions <NUM>, and may include a guide groove <NUM> and a guide protrusion <NUM> to be coupled to each other.

The central wall 500a may include a first central wall 510a and a second central wall 520a. The first central wall 510a may have the same structure as the second central wall 520a. For example, the first central wall 510a and the second central wall 520a may be rotated by <NUM>° around a first axis. According to another embodiment of the present disclosure, the first central wall 510a and the second central wall 520a may be manufactured to be the same as each other and coupled to the sub-module <NUM> having the same structure, and a manufacturing process of the battery module <NUM> may be simplified.

As shown in <FIG>, the first central wall 510a and the second central wall 520a may include a guide groove <NUM> and a guide protrusion <NUM> on one surface thereof, respectively. While the first central wall 510a and the second central wall 520a contact each other, one surface on which the guide groove <NUM> and the guide protrusion <NUM> are formed may be in contact with each other.

A guide protrusion <NUM> and a guide groove <NUM> may be formed on an opposite surface of the surface on which the groove portion <NUM> is formed. The guide groove <NUM> and the guide protrusion <NUM> may be formed to be symmetrical with respect to a centerline C in a longitudinal direction (e.g., the third direction (Y-direction)) of the center wall 500a. Therefore, when the first central wall 510a and the second central wall 520a are coupled, the guide groove <NUM> of the first central wall <NUM> and the guide protrusion <NUM> of the second central wall <NUM> may be in contact with each other, the guide protrusion <NUM> of the first central wall 510a and the guide groove <NUM> of the second central wall 520a may be in contact with each other. The guide protrusion <NUM> and the guide groove <NUM> may correspond to each other, and in the battery module <NUM>, the first central wall 510a and the second central wall 520a may be in close contact with each other. Therefore, since a space between the central walls 510a and 520a does not exist, a space-saving efficiency in the battery module <NUM> may be secured.

The guide protrusion <NUM> may include a through-hole <NUM>. The through-hole <NUM> may be formed to have a length in the first direction (Z-direction). As the through-hole <NUM> is formed, an empty space may be formed inside the guide protrusion <NUM>. Thus, an empty space may be formed inside the central wall <NUM>, and a weight of the battery module <NUM> including the central wall <NUM> may be reduced.

<FIG>, <FIG> illustrate a central wall 500a according to one embodiment of the present disclosure.

The central wall 500a according to this embodiment of the present disclosure may include a plurality of groove portions <NUM> on one surface thereof. A plurality of groove portions <NUM> may be formed on one surface of the central wall 510a or 520a. For example, the plurality of groove portions <NUM> may be formed to have a length in a first direction (Z-direction). Referring to <FIG>, one surface of the central wall 500a on which the plurality of groove portions <NUM> are formed may be disposed in a direction facing the sub-module <NUM>. Referring to <FIG>, the groove portion <NUM> of the first central wall 510a may extend in the first direction (Z-direction) and have depth in the second direction (X-direction) direction and be formed in a direction from the first central wall 510a toward the first sub-module <NUM>, and the groove portion <NUM> of the second central wall 520a may extend in the first direction (Z-direction) and have depth in the second direction (X-direction) be formed in a direction from the second central wall 520a toward the second sub-module <NUM>. Heat or gas may be generated in battery cells <NUM> of the sub-module <NUM>, and the heat or gas may propagate to the central wall 500a. In this case, the groove portion <NUM> of the central wall 500a may function similarly to a vent hole, and the heat or gas emitted from the sub-module <NUM> may move in the groove portion <NUM> to both ends thereof in the first direction (Z-direction). The heat propagated to both ends thereof in the first direction (Z-direction) may move to a heat sink <NUM> disposed below a lower cover <NUM> and be cooled.

The central wall 500a according to another embodiment of the present disclosure may include a first fastening groove <NUM> to be coupled to the side cover <NUM>. That is, the central wall 500a may be connected to the side cover <NUM>, and a fastening member <NUM> may be coupled to the first fastening groove <NUM>. Thus, the side cover <NUM> may be fixed without applying external force to fix the side cover <NUM>. The first fastening groove <NUM> may be formed on a side surface, adjacent to one side surface on which the groove portion <NUM> is formed. For example, the first fastening groove <NUM> may be formed to have a length in a third direction (Y-direction).

The central wall 500a may include a second fastening groove <NUM> to be coupled to an upper cover <NUM> and a lower cover <NUM>. The second fastening groove <NUM> may be connected to the upper cover <NUM> and the lower cover <NUM> and may be fastened through the fastening member <NUM>. Therefore, in the battery module <NUM> according to one embodiment of the present disclosure, the upper cover <NUM> and the lower cover <NUM> may be fixed by being coupled to the central wall 500a. The second fastening groove <NUM> may be formed on a side surface, adjacent to one side surface on which the groove portion <NUM> is formed, and may be formed on a side, other than the side on which the first fastening groove <NUM> is formed. For example, the second fastening groove <NUM> may be formed to have a length in the first direction (Z-direction). Referring to <FIG>, a plurality of second fastening grooves <NUM> may be provided.

<FIG>, <FIG> illustrate a central wall 500b according to another embodiment of the present disclosure.

In a central wall 500b, a groove portion <NUM> may be formed in a structure in which the groove portion <NUM> expands inwardly from outer surface of the central wall 500b to inner side of the central wall 500b. As the groove portion <NUM> thereinside extends, heat or gas that has moved to the central wall 500b may be easily accommodated in the groove portion <NUM>. Accordingly, the accommodated heat or gas can move along the groove portion <NUM> in a first direction (Z-direction).

In the central wall 500b, the groove portion <NUM> may be expanded so that an empty space may be additionally formed inside the central wall 500b. Accordingly, a weight of the central wall 500b may be reduced, and a weight of the battery module <NUM> including the central wall 500b may be reduced.

The central wall 500b may include a first fastening groove <NUM> and a second fastening groove <NUM>, like the central wall 500a of the earlier embodiment of the present disclosure, and may include a guide protrusion <NUM> and a guide groove <NUM>. The guide protrusion <NUM> and the guide groove <NUM> of the central wall 500b may be formed to be symmetrical with respect to a centerline C of the central wall <NUM> in a longitudinal direction (e.g., third direction (Y-direction).

As set forth above, in at least some embodiments of the present disclosure, a manufacturing process may be simplified by including the same sub-module.

In at least some embodiments of the present disclosure, a central wall may be connected to a side cover to improve mechanical rigidity.

Claim 1:
A battery module (<NUM>) comprising:
a first sub-module (<NUM>) and a second sub-module (<NUM>) respectively including a cell stack (<NUM>) in which a plurality of battery cells (<NUM>) are stacked; and
a central wall (<NUM>, 500a, 500b) disposed between the first sub-module (<NUM>) and the second sub-module (<NUM>),
wherein the central wall (<NUM>, 500a, 500b) includes:
a first central wall (<NUM>, 510a) facing the first sub-module (<NUM>) and a second central wall (<NUM>, 520a) facing the second sub-module (<NUM>), and
a guide groove (<NUM>) and a guide protrusion (<NUM>) coupling the first central wall (<NUM>, 510a) and the second central wall (<NUM>, 520a),
wherein the guide groove (<NUM>) and the guide protrusion (<NUM>) are formed on each of the first central wall (<NUM>, 510a) and the second central wall (<NUM>, 520a) and disposed to face each other,
characterized in that the first central wall (<NUM>, 510a) has a rotationally symmetrical shape to the second central wall (<NUM>, 520a) around a first axis, and
wherein the guide groove (<NUM>) of the first central wall (<NUM>, 510a) and the guide groove (<NUM>) of the second central wall (<NUM>, 520a) are disposed to be rotationally symmetrical around the first axis.