Patent Description:
The present invention relates to a battery module including a cooling member, a battery pack including the battery module, and an electrical device, and more particularly, to a battery module with improved manufacturing efficiency and improved cooling efficiency.

Recently, as the demand for portable electronic products such as laptops, video cameras and portable telephones has rapidly increased and the development of electric vehicles, energy storage batteries, robots, satellites, and the like is being performed in earnest, a high-performance secondary battery capable of repetitive charging and discharging is being actively studied.

The lithium secondary battery mainly uses lithium-based oxides and carbonaceous materials as a positive electrode active material and a negative electrode active material, respectively. In addition, the lithium secondary battery includes an electrode assembly in which a positive electrode plate coated with the positive electrode active material and a negative electrode plate coated with the negative electrode active material are disposed with a separator being interposed therebetween, and an exterior, namely a battery case, hermetically containing the electrode assembly together with an electrolyte.

In addition, the lithium secondary battery may be classified into a can-type secondary battery in which an electrode assembly is embedded in a metal can and a pouch-type secondary battery in which an electrode assembly is embedded in a pouch made of an aluminum laminate sheet, depending on the shape of its exterior.

Here, a metal can of the can-type secondary battery in which the electrode assembly is embedded may be manufactured in a cylindrical shape. The can-type secondary battery may be used to configure a battery module, which includes a module case for accommodating a plurality of secondary batteries and a bus bar configured to electrically connect the plurality of secondary batteries.

In addition, the conventional battery module includes a heatsink to discharge heat generated from the module case including a plurality of secondary batteries to the outside. In particular, in the conventional art, a cooling plate for heat conduction is generally interposed between the module case and a heatsink.

However, the cooling plate interposed between the module case and the heatsink may lengthen a heat transfer path and reduce the heat conduction efficiency. Moreover, if the cooling plate is welded to the module case and the heatsink, respectively, components are likely to thermally deform. Also, a plurality of members should be welded to each other, there is a problem of lowering the manufacturing process efficiency.

Further prior art is described in <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

The present invention is designed to solve the problems of the related art, and therefore it is an object of the present invention to provide a battery module, a battery pack, and an electric device comprising the same, with improved manufacturing efficiency and improved cooling efficiency.

These and other objects and advantages of the present invention may be understood from the following detailed description and will become more fully apparent from the exemplary embodiments of the present invention. Also, it will be easily understood that the objects and advantages of the present invention may be realized by the means shown in the appended claims and combinations thereof.

This object is accomplished with a battery module, a battery pack and an electronic device comprising the features of claims <NUM>, <NUM> and <NUM>, respectively.

Dependent claims are directed on preferred embodiments of the invention.

According to an embodiment of the present invention, since the cooling member is coupled to the upper frame and the upper frame to which the plurality of secondary batteries are mounted and the coolant channel is provided to the lower frame, the plurality of secondary batteries may directly contact the upper surface of the cooling member without any additional heat conductive member interposed therebetween, thereby improving the cooling efficiency.

Moreover, according to another embodiment of the present invention, since the lower frame of the cooling member is configured to be bonded to the other surface of the upper frame, the cooling member may be assembled without a separate fastening member. Accordingly, in the present invention, it is possible to reduce the number of parts and shorten the manufacturing time, compared to the conventional art, thereby reducing the manufacturing cost.

In addition, according to another embodiment of the present invention, since both side portions of the upper frame and the lower frame are welded to each other, the bonding strength between the upper frame and the lower frame may be further increased. Accordingly, in the present invention, when an external shock occurs while the battery module is in use, it is possible to further prevent the coolant from leaking through the gap between the upper frame and the lower frame due to a crack generated at the cooling member.

The accompanying drawings illustrate a preferred embodiment of the present invention and together with the foregoing invention, serve to provide further understanding of the technical features of the present invention, and thus, the present invention is not construed as being limited to the drawing.

Prior to the description, it should be understood that the terms used in the specification and the appended claims should not be construed as limited to general and dictionary meanings, but interpreted based on the meanings and concepts corresponding to technical aspects of the present invention on the basis of the principle that the inventor is allowed to define terms appropriately for the best explanation.

Therefore, the description proposed herein is just a preferable example for the purpose of illustrations only, not intended to limit the scope of the invention.

<FIG> is a perspective view schematically showing a battery module according to an embodiment of the present invention. Also, <FIG> is an exploded perspective view schematically showing components of the battery module according to an embodiment of the present invention. For reference, the X-axis shown in <FIG> refers to a right and left direction, the Y-axis refers to a front and rear direction, and the Z-axis refers to an upper and lower direction.

Referring to <FIG> and <FIG>, a battery module <NUM> according to an embodiment of the present invention may include a plurality of secondary batteries <NUM> and a cooling member <NUM>.

Here, the secondary battery <NUM> may be a cylindrical battery cell. In the cylindrical battery cell, a negative electrode terminal 211b may be formed at an upper portion (an upper corner portion) of a battery can. The cylindrical battery cell may have a battery cap provided at an upper portion thereof, and a positive electrode terminal 211a may be formed at the center of the battery cap. The battery can may include an electrode assembly (not shown) accommodated therein. The battery can and the battery cap may be electrically insulated from each other. Since the configuration of the cylindrical battery cell is widely known to those skilled in the art at the time of filing of this application, it will not be described in more detail in this specification.

Moreover, the plurality of secondary batteries <NUM> may be disposed to be spaced apart from each other by a distance of <NUM>, for example. In addition, a plurality of secondary batteries <NUM> located in one row and a plurality of secondary batteries <NUM> located in another row may be arranged to be positioned differently in a front and rear direction (X-axis direction). In addition, the plurality of secondary batteries <NUM> located in one row and the plurality of secondary batteries <NUM> located in another row may be arranged to be positioned differently in a left and right direction. That is, the plurality of secondary batteries <NUM> may be regarded as being arranged in a zigzag pattern in front, rear, left and right directions as a whole.

In addition, the plurality of secondary batteries <NUM> may be electrically connected in series or in parallel by a bus bar (not shown) having a conductive metal. The bus bar may include, for example, at least one of copper, nickel and aluminum. For example, the bus bar may be in the form of a wire. The bus bar may electrically connect the positive electrode terminals 211a located on the battery cap at the upper portion of the secondary battery <NUM> (a positive direction of the Z-axis in <FIG>) and/or negative electrode terminals 211b formed on the battery can to each other.

Meanwhile, referring to <FIG> and <FIG> again, the cooling member <NUM> may include an upper frame <NUM> and a lower frame <NUM>. Specifically, the upper frame <NUM> may have a plate shape with a predetermined length so that the plurality of secondary batteries <NUM> may be mounted to one surface (an upper surface) thereof.

In addition, the lower frame <NUM> may have an upper portion corresponding to the plane size of the upper frame <NUM>. The lower frame <NUM> may be coupled to the other surface of the upper frame <NUM>. The lower frame <NUM> may include a coolant channel D configured so that a coolant flows therethrough.

Specifically, the cooling member <NUM> may have an inlet I and an outlet O. The inlet I may be configured to inject a cooled coolant from an external device. The outlet O may be configured such that a coolant absorbing heat from the plurality of secondary batteries <NUM> is discharged toward the external device. The coolant channel D may be connected to the inlet I and the outlet O, respectively.

That is, one end of the coolant channel D may communicate with the inlet I. The other end of the coolant channel D may communicate with the outlet O. The coolant channel D may include a moving path configured to protrude relatively downward to form an empty space through which the coolant may flow, and a barrier W configured to protrude upward to partition the moving path. Here, the coolant may be water, for example.

Therefore, according to this configuration of the present invention, since the cooling member <NUM> is coupled to the upper frame <NUM> and the upper frame <NUM> to which the plurality of secondary batteries <NUM> are mounted and the coolant channel is provided to the lower frame <NUM>, the plurality of secondary batteries <NUM> may directly contact the upper surface of the cooling member <NUM> without any additional heat conductive member interposed therebetween, thereby improving the cooling efficiency.

In addition, the upper frame <NUM> may be manufactured by a pressing method so as not to be susceptible to thermal deformation caused by welding or the like. For example, the upper frame <NUM> may be made of a metal material such as steel, aluminum and stainless steel. That is, since the upper frame <NUM> is manufactured by a pressing method, thermal deformation may not be severely generated. Accordingly, in the present invention, it is possible to prevent the contact area of the plurality of secondary batteries <NUM> in contact with one surface of the upper frame <NUM> from being reduced, since thermal deformation of the upper frame <NUM> is less generated by the heat generated by charging and discharging of the battery module <NUM>.

Moreover, the lower frame <NUM> may be manufactured by an injection method. The lower frame <NUM> may be made of a plastic material. The plastic material may be, for example, an engineering plastic. Since some components of the cooling structure is made of plastic that a lightweight material, it is possible to reduce the weight of the battery module <NUM>.

<FIG> is a vertical sectional view schematically showing the battery module, taken along the line C-C' of <FIG>.

Referring <FIG> along with <FIG> and <FIG>, the coolant channel D of the lower frame <NUM> may have an uneven structure K with a portion 226a protruding toward the upper frame <NUM> in cross section. Here, the portion 226a protruding toward the upper frame <NUM> may be an upper surface of each of the barrier W of the lower frame <NUM> and the outer peripheral portion of the lower frame <NUM>.

More specifically, the portion 226a of the uneven structure K protruding toward the upper frame <NUM> may be configured to be bonded to the other surface (a lower surface) of the upper frame <NUM>. At this time, the bonding may be performed using an adhesive. The adhesive is not limited to a specific material and, for example, the adhesive may be a glue or a hot-melt resin. For example, the adhesive may include at least one of a polyamide resin, a polyimide resin, an epoxy resin, and an acrylic resin.

Therefore, according to this configuration of the present invention, since the lower frame <NUM> of the cooling member <NUM> is configured to be bonded to the other surface of the upper frame <NUM>, the cooling member <NUM> may be assembled without a separate fastening member. Accordingly, in the present invention, it is possible to reduce the number of parts and shorten the manufacturing time, compared to the conventional art, thereby reducing the manufacturing cost.

<FIG> is a perspective view schematically showing some components of a battery module according to another embodiment of the present invention.

Referring to <FIG>, unlike the cooling member <NUM> of <FIG> in which the upper frame <NUM> and the lower frame <NUM> are coupled using only an adhesive, the cooling member <NUM> of <FIG> may have a portion in which the upper frame <NUM> and the lower frame <NUM> are coupled (joined) by welding.

For example, as shown in <FIG>, the cooling member <NUM> of <FIG> may have a portion J1 in which both side portions of the upper frame <NUM> and the lower frame <NUM> are joined to each other by at least one of spot welding, arc welding and laser welding. However, it is not limited to welding methods, and any known applicable welding method may be used.

Therefore, according to this configuration of the present invention, since both side portions of the upper frame <NUM> and the lower frame <NUM> are welded to each other, the bonding strength between the upper frame <NUM> and the lower frame <NUM> may be further increased. Accordingly, in the present invention, when an external shock occurs while the battery module <NUM> is in use, it is possible to further prevent the coolant from leaking through the gap between the upper frame <NUM> and the lower frame <NUM> due to a crack generated at the cooling member <NUM>.

<FIG> is a vertical sectional view schematically showing some components of a battery module according to still another embodiment of the present invention.

Referring to <FIG>, unlike the cooling member <NUM> of <FIG> in which the upper frame <NUM> and the lower frame <NUM> are coupled using only an adhesive, the cooling member <NUM> of <FIG> may have a portion in which the upper frame <NUM> and the lower frame <NUM> are coupled to each other by mechanical joining. For example, as shown in <FIG>, both side portions of the upper frame <NUM> and the lower frame <NUM> may be coupled to each other by riveting, which is a mechanical joining method. The riveting is a process of joining two members to each other by penetrating a rivet R through the upper frame <NUM> and the lower frame <NUM>, respectively.

<FIG> is a perspective view schematically showing some components of a battery module according to still another embodiment of the present invention.

Referring to <FIG>, both side portions of the upper frame <NUM> and the lower frame <NUM> may have a portion J2 in which the upper frame <NUM> and the lower frame <NUM> are coupled to each other using at least one of TOX clinching and clinching. As shown in <FIG>, in the portion J2 the upper frame <NUM> and the lower frame <NUM> are joined to each other, a space J indented inward by TOX clinching or clinching may be formed.

For example, by the clinching, portions of the upper frame <NUM> and the lower frame <NUM> may be joined to each other in a state of overlapping with each other by applying a cold forming method. In addition, the TOX clinching is a process in which portions of the upper frame <NUM> and the lower frame <NUM> are plastically deformed in a state of overlapping with each other to be joined.

Therefore, according to this configuration of the present invention, since both side portions of the upper frame <NUM> and the lower frame <NUM> are coupled to each other using a mechanical joining method, the bonding force between the upper frame <NUM> and the lower frame <NUM> may be further enhanced. Accordingly, in the present invention, it is possible to further prevent the coolant from leaking through the gap between the upper frame <NUM> and the lower frame <NUM> due to a crack generated in the cooling member <NUM> when an external shock occurs while the battery module <NUM> is in use.

<FIG> is a perspective view schematically showing a battery module according still another embodiment of the present invention.

Referring to <FIG>, a cooling member 220A of a battery module 200A of <FIG> may further include sidewalls 221w provided at both side ends of the upper frame <NUM>, respectively. The sidewall 221w may have a shape extending upward from each of both side ends of the upper frame <NUM> having a plate shape. The sidewall 221w may be formed integrally with the upper frame <NUM>. For example, as shown in <FIG>, the upper frame <NUM> of the cooling member <NUM> of the present invention may include a left sidewall 221w and a right sidewall 221w respectively provided at left and right ends in the X direction. The sidewall 221w may have a shape elongating in a front and rear direction (Y-axis direction).

Therefore, according to this configuration of the present invention, since the sidewalls 221w respectively extending upward from both side ends of the upper frame <NUM> are further provided, it is possible to prevent the cooling member <NUM> from being bent in a vertical direction. That is, the sidewall 221w may serve as a reinforcing member for reinforcing the rigidity of the cooling member <NUM> to prevent the cooling member <NUM> from being bent due to the plurality of secondary batteries <NUM> mounted on the cooling member <NUM>.

<FIG> is a perspective view schematically showing some components of a battery module according to still another embodiment of the present invention. Also, <FIG> is a vertical sectional view schematically showing some components of the battery module of <FIG>.

Referring to <FIG> and <FIG>, the cooling member <NUM> of the battery module of <FIG> may further include a clip member <NUM>. The clip member <NUM> may be configured to fix both side ends of the upper frame <NUM> and the lower frame <NUM> to each other. Specifically, the clip member <NUM> may include a body portion <NUM> and a fixing portion <NUM>. The body portion <NUM> may elongate along one surface of the upper frame <NUM> and configured to be in close contact with one surface of the upper frame <NUM>. The fixing portion <NUM> may be bent from the body portion <NUM> to surround both ends of the upper frame <NUM> and the lower frame <NUM>.

For example, as shown in <FIG>, the body portion <NUM> of the clip member <NUM> may have a shape elongating in a left and right direction (X-axis direction) along the upper surface of the upper frame <NUM>. The body portion <NUM> may be in close contact with the upper surface of the upper frame <NUM> to limit deformation of the upper frame <NUM> so as to prevent the upper frame <NUM> from being bent.

For example, as shown in <FIG>, the fixing portion <NUM> of the clip member <NUM> may include a first bent portion 233a and a second bent portion 233b to surround both ends of the upper frame <NUM> and the lower frame <NUM>. The first bent portion 233a may be a portion bent downward from left and right ends the body portion <NUM>. The second bent portion 233b may be a portion bent inward (toward the center) from a lower end of the first bent portion 233a.

Therefore, according to this configuration of the present invention, since the clip member <NUM> is further provided, the body portion <NUM> of the clip member <NUM> serves as a reinforcing member for reinforcing rigidity to prevent the cooling member <NUM> from being bent due to the plurality of secondary batteries <NUM> mounted on the cooling member <NUM>.

Moreover, the fixing portion <NUM> of the clip member <NUM> may be bent to surround both side ends of the upper frame <NUM> and the lower frame <NUM>, thereby preventing both side ends of the upper frame <NUM> and the lower frame <NUM> from being separated. Accordingly, in the present invention, by means of the clip member <NUM>, it is possible to further prevent the coolant from leaking through the gap between the upper frame <NUM> and the lower frame <NUM> due to a crack generated at the cooling member <NUM> when an external shock occurs while the battery module <NUM> is in use.

<FIG> is a plan view schematically showing some components of a battery module according to still another embodiment of the present invention. Also, <FIG> is a horizontal sectional view schematically showing the battery module, taken along the line A-A' of <FIG>.

Referring to <FIG>, a cooling member 220B of <FIG> may include a plurality of guide protrusions P provided at on the upper surface of the upper frame <NUM>. The guide protrusions P may have a shape protruding from the upper surface of the upper frame <NUM> toward the secondary batteries <NUM> (in a positive direction of the Z-axis in <FIG>) to guide mounting locations of the plurality of secondary batteries <NUM>.

That is, the guide protrusion P may have a circular shape in a plane so as to surround the outer peripheral portion of the lower end of the secondary battery <NUM>. In addition, one secondary battery <NUM> may be mounted inside the circular guide protrusion P.

Therefore, according to this configuration of the present invention, since the guide protrusion P is provided at the upper frame <NUM> of the cooling member 220B, the plurality of secondary batteries <NUM> may be easily disposed at correct locations, and the contact area between the upper frame <NUM> and the plurality of secondary batteries <NUM> may be increased, thereby effectively enhancing the cooling efficiency of the cooling member.

Meanwhile, a battery pack (not shown) according to an embodiment of the present invention includes at least one battery module <NUM>. In addition, the battery pack may further include various devices (not shown) for controlling charging and discharging of the battery module <NUM>, for example a battery management system (BMS), a current sensor, and a fuse.

Meanwhile, an electrical device (not shown) according to an embodiment of the present invention includes at least one battery module <NUM> described above. The electrical device may further include a device housing (not shown) having an accommodation space for accommodating the battery module <NUM>, and a display unit through which a user may check the state of charge of the battery module <NUM>.

In addition, the battery pack according to an embodiment of the present invention may be provided to a vehicle such as an electric vehicle or a hybrid electric vehicle. That is, the vehicle according to an embodiment of the present invention may be equipped with a battery pack including at least one battery module <NUM> according to an embodiment of the present invention described above, to be mounted in a vehicle body.

Meanwhile, even though the terms indicating directions such as upper, lower, left, right, front and rear directions are used in the specification, it is obvious to those skilled in the art that these merely represent relative positions for convenience in explanation and may vary based on a position of an observer or an object.

Claim 1:
A battery module (<NUM>), comprising:
a plurality of secondary batteries (<NUM>); and
a cooling member (<NUM>) configured so that the plurality of secondary batteries (<NUM>) are mounted thereto,
wherein the cooling member (<NUM>) includes:
an upper frame (<NUM>) having a plate shape with a predetermined length so that the plurality of secondary batteries (<NUM>) are mounted to one surface thereof; and
a lower frame (<NUM>) coupled to the other surface of the upper frame (<NUM>) and having a coolant channel (D) configured so that a coolant flows therethrough,
wherein the cooling member (<NUM>) further includes a clip member (<NUM>) configured to fix both side ends of the upper frame (<NUM>) and the lower frame (<NUM>) to each other,
characterized in that the clip member (<NUM>) includes:
a body portion (<NUM>) configured to elongate along one surface of the upper frame (<NUM>) and provided in close contact with the upper frame (<NUM>); and
a fixing portion (<NUM>) bent from the body portion (<NUM>) to surround both ends of the upper frame (<NUM>) and the lower frame (<NUM>).