Patent Description:
Secondary batteries widely used at the preset include lithium ion batteries, lithium polymer batteries, nickel cadmium batteries, nickel hydrogen batteries, nickel zinc batteries and the like. 5V to <NUM>.

Meanwhile, when a plurality of battery cells are connected in series or in parallel to configure a battery pack, it is common to configure a battery module composed of at least one battery cell first, and then configure a battery pack by using at least one battery module and adding other components.

If a fire occurs in battery cells inside a module case that accommodates the battery cells, the battery module is necessary to exhaust only the gas without expelling the flame out of the module case for safety.

However, the conventional battery module generally does not include a structure for discharging only the exhaust gas while preventing flame leak when a fire situation occurs due to thermal runaway of the battery cells.

Therefore, when a fire situation occurs due to the thermal runaway of the battery cells, it is demanded to find a way to prevent flame leak to the outside of the module case and to discharge the exhaust gas out of the module case.

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

The present disclosure is directed to providing a battery module, which may prevent a flame leak to the outside of a module case and also discharge an exhaust gas out of the module case when a fire situation occurs due to thermal runaway of battery cells, and a battery pack and a vehicle including the battery module.

In one aspect of the present disclosure, there is provided a battery module, comprising: at least one battery cell assembly including at least one battery cell; a module case configured to accommodate the at least one battery cell assembly; and an exhaust housing coupled to the module case to cover the at least one battery cell assembly, the exhaust housing having at least one gas discharge hole for discharging a gas inside the module case and a plurality of flame leak prevention partitions for variably adjusting a length thereof, wherein the exhaust housing includes a housing base configured to cover an upper side of the module case; the plurality of flame leak prevention partitions fixed to the housing base; a pipe unit fixed on the plurality of flame leak prevention partitions and configured to communicate with the module case and the at least one gas discharge hole; and a housing cover configured to cover the pipe unit and coupled to the housing base, wherein the plurality of flame leak prevention partitions are configured to variably perform multi-stage sliding along a width direction of the housing base.

The plurality of flame leak prevention partitions may have a length designed to be variable along a width direction of the module case according to a user manipulation.

The housing base may have a plurality of partition insert grooves into which the plurality of flame leak prevention partitions are inserted.

The pipe unit may include a plurality of pipe connectors coupled to the housing cover and the housing base; and a plurality of pipe cylinders configured to communicate with the plurality of pipe connectors and fixed on the plurality of flame leak prevention partitions.

Each of the plurality of pipe cylinders may include a plurality of cylinder tubes having a predetermined length and coupled to the plurality of pipe connectors; and at least one cylinder grid configured to connect the plurality of cylinder tubes to each other.

In addition, the present disclosure provides a battery pack, comprising: at least one battery module according to the above embodiments; and a pack case configured to package the at least one battery module.

Moreover, the present disclosure provides a vehicle, comprising at least one battery pack according to the above embodiment.

According to various embodiments as described above, it is possible to provide a battery module, which may prevent a flame leak to the outside of a module case and also discharge an exhaust gas out of the module case when a fire situation occurs due to thermal runaway of battery cells, and a battery pack and a vehicle including the battery module.

<FIG> is a diagram for illustrating a battery module according to an embodiment of the present disclosure, and <FIG> is an exploded perspective view showing the battery module of <FIG>.

Referring to <FIG> and <FIG>, the battery module <NUM> includes a battery cell assembly <NUM>, a module case <NUM>, fastening members <NUM>, and an exhaust housing <NUM>.

At least one battery cell assembly <NUM> or a plurality of battery cell assemblies <NUM> may be provided. The battery cell assembly <NUM> may include one or more battery cells <NUM>. Hereinafter, in this embodiment, it will be described that the battery cell assembly <NUM> includes a plurality of battery cells <NUM>.

The plurality of battery cells <NUM> are secondary batteries, and may be provided as pouch-type secondary batteries, rectangular secondary batteries or a cylindrical secondary batteries. Hereinafter, in this embodiment, it will be described that the plurality of battery cells <NUM> are pouch-type secondary batteries.

The module case <NUM> accommodates the at least one battery cell assembly <NUM>. To this end, an accommodation space for accommodating the at least one battery cell assembly <NUM> is provided in the module case <NUM>.

The module case <NUM> has a plurality of fastening holes <NUM> for coupling with the exhaust housing <NUM>, explained later. The plurality of fastening holes <NUM> are provided to be spaced apart from each other by a predetermined distance along an edge of the module case <NUM>.

The fastening members <NUM> connect the module case <NUM> and the exhaust housing <NUM>, explained later, to each other.

The plurality of fastening members <NUM> include a plurality of fastening bolts <NUM> and a plurality of fastening nuts <NUM>.

The plurality of fastening bolts <NUM> pass through the exhaust housing <NUM>, explained later, and the fastening holes <NUM> of the module case <NUM> and be fastened with the fastening nuts <NUM>, respectively.

When a fire situation occurs inside the module case <NUM>, the exhaust housing <NUM> prevents flame generated by the fire from being discharged to the outside of the module case <NUM> and discharge a gas out of the module case <NUM>. Since the battery module <NUM> according to this embodiment discharges only the gas to the outside through the exhaust housing <NUM> while suppressing the flame emission when the fire situation occurs, it is possible to prevent a greater damage from being caused by the fire situation in advance.

In the following, the exhaust housing <NUM> will be described in more detail.

<FIG> is an exploded perspective view showing the exhaust housing of the battery module of <FIG>.

Referring to <FIG>, the exhaust housing <NUM> is coupled to the module case <NUM> (see <FIG>) to cover the at least one battery cell assembly <NUM> (see <FIG>). Also, the exhaust housing <NUM> includes at least one gas discharge hole <NUM> for discharging the gas inside the module case <NUM>, and at least one flame leak prevention partition <NUM> capable of variably adjusting the length thereof.

Hereinafter, the structure of the exhaust housing <NUM> will be described in more detail.

<FIG> is a diagram for illustrating a housing base of the exhaust housing of <FIG>.

Referring to <FIG>, the housing base <NUM> covers an upper side of the module case <NUM> (see <FIG>). The housing base <NUM> includes a case fastening hole <NUM>, a partition insert groove <NUM>, the gas discharge hole <NUM>, and a sealing member insert groove <NUM>.

The case fastening hole <NUM> is provided in plural, and the plurality of case fastening holes <NUM> are arranged to be spaced apart from each other by a predetermined distance along the edge of the housing base <NUM>. The fastening bolts <NUM> of the fastening member <NUM> penetrate the plurality of case fastening holes <NUM>.

The partition insert grooves <NUM> are provided on an upper side of the bottom of the housing base <NUM>, and are formed in a predetermined length along the width direction of the housing base <NUM>. The flame leak prevention partitions <NUM>, explained later, are inserted into the partition insert grooves <NUM>.

The partition insert groove <NUM> is provided in plural. The plurality of partitions insert grooves <NUM> are disposed to be spaced apart from each other by a predetermined distance along the length direction of the housing base <NUM>.

The gas discharge hole <NUM> may be provided in the bottom of the housing base <NUM>. The gas discharge hole <NUM> is provided to communicate with the inside of the module case <NUM> (see <FIG>).

The gas discharge hole <NUM> may be provided in plural. The plurality of gas discharge holes <NUM> may be provided near both edges of the bottom of the housing base <NUM>.

The sealing member insert groove <NUM> may be provided at an edge of the upper surface of the housing base <NUM>. The sealing member insert groove <NUM> may be provided between the plurality of case fastening holes <NUM> and the partition insert groove <NUM>.

<FIG> is a diagram for illustrating a flame leak prevention partition of the exhaust housing of <FIG>, and <FIG> are diagrams for illustrating a sliding operation of the flame leak prevention partition of <FIG>.

Referring to <FIG>, the flame leak prevention partition <NUM> is provided in plural. The plurality of flame leak prevention partitions <NUM> secure a predetermined rigidity while acting as a bead, thereby securing rigidity to suppress the explosive force when a fire situation occurs.

In addition, the plurality of flame leak prevention partitions <NUM> have a predetermined height, and serve as the beads when a fire situation occurs to minimize flame propagation to the surrounding area.

The flame leak prevention partition <NUM> may be provided to have a length variable along the width direction of the module case <NUM> (see <FIG>) according to a user manipulation. Specifically, the flame leak prevention partition <NUM> may be provided to perform multi-stage sliding along the width direction. More specifically, the flame leak prevention partition <NUM> may be provided to variably perform multi-stage sliding along the width direction of the housing base <NUM>.

The flame leak prevention partition <NUM> may be fixed to the housing base <NUM>. Specifically, the flame leak prevention partition <NUM> may be inserted into and mounted to the partition insert groove <NUM> of the housing base <NUM>.

The flame leak prevention partition <NUM> may include a plurality of partitions <NUM>, <NUM>, <NUM>, <NUM> for the multi-stage sliding.

The plurality of partitions <NUM>, <NUM>, <NUM>, and <NUM> may include a first partition <NUM>, a second partition <NUM>, a third partition <NUM>, and a fourth partition <NUM>.

When mounted to the housing base <NUM>, the first partition <NUM> may be disposed at one end of the housing base <NUM> in the width direction. A plurality of pipe storage boxes <NUM> may be formed at an upper side of the first partition <NUM>. A pipe cylinder <NUM> of a pipe unit <NUM>, explained later, may be fixed to the plurality of pipe storage boxes <NUM>.

The first partition <NUM> may have a sliding groove <NUM> for guiding the sliding of the second partition <NUM>, explained later. The sliding groove <NUM> is provided at both sides of the inner surface of the first partition <NUM>, and may guide variable sliding of the second partition <NUM>, explained later, along the width direction of the housing base <NUM>.

The second partition <NUM> may be mounted to the first partition <NUM> to be slidable from the first partition <NUM>. The plurality of pipe storage boxes <NUM> may be formed at an upper side of the second partition <NUM>. The pipe cylinder <NUM> of the pipe unit <NUM>, explained later, may be fixed to the plurality of pipe storage boxes <NUM>.

The second partition <NUM> may include a sliding groove <NUM> and a sliding protrusion <NUM>.

The sliding groove <NUM> may guide the sliding of the third partition <NUM>, explained later. The sliding groove <NUM> is provided at both sides of the inner surface of the second partition <NUM>, and may guide variable sliding of the third partition <NUM>, explained later, along the width direction of the housing base <NUM>.

The sliding protrusion <NUM> may be provided at both sides of the outer surface of the second partition <NUM>. The sliding protrusion <NUM> of the second partition <NUM> may be slidably mounted to the sliding groove <NUM> of the first partition <NUM>.

The third partition <NUM> may be mounted to the second partition <NUM> to be slidable from the second partition <NUM>. A plurality of pipe storage boxes <NUM> may be formed at an upper side of the third partition <NUM>. A pipe cylinder <NUM> of a pipe unit <NUM>, explained later, may be fixed to the plurality of pipe storage boxes <NUM>.

The third partition <NUM> may include a sliding groove <NUM> and a sliding protrusion <NUM>.

The sliding groove <NUM> may guide the sliding of the fourth partition <NUM>, explained later. The sliding groove <NUM> is provided at both sides of the inner surface of the third partition <NUM>, and may guide variable sliding of the fourth partition <NUM>, explained later, along the width direction of the housing base <NUM>.

The sliding protrusion <NUM> may be provided at both sides of the outer surface of the third partition <NUM>. The sliding protrusion <NUM> of the third partition <NUM> may be slidably mounted to the sliding groove <NUM> of the second partition <NUM>.

The fourth partition <NUM> may be mounted to the third partition <NUM> to be slidable from the third partition <NUM>. At least one pipe storage box <NUM> may be formed at an upper side of the fourth partition <NUM>. A pipe cylinder <NUM> of a pipe unit <NUM>, explained later, may be fixed to the at least one pipe storage box <NUM>.

The fourth partition <NUM> may include a sliding protrusion <NUM>.

The sliding protrusion <NUM> may be provided at both sides of the outer surface of the fourth partition <NUM>. The sliding protrusion <NUM> of the fourth partition <NUM> may be slidably mounted to the sliding groove <NUM> of the third partition <NUM>.

The sliding operation of the first partition <NUM> to the fourth partition <NUM> will be described as follows. For example, the fourth partition <NUM> may be inserted into the third partition <NUM> by sliding toward the third partition <NUM> through a user manipulation or the like. In this case, a three-stage partition structure of the first partition <NUM> to the third partition <NUM> may be formed.

Also, for example, the third partition <NUM> may be inserted into the second partition <NUM> by sliding toward the second partition <NUM> through a user manipulation or the like. In this case, a two-stage partition structure of the first partition <NUM> and the second partition <NUM> may be formed.

Moreover, for example, the second partition <NUM> may be inserted into the first partition <NUM> by sliding toward the first partition <NUM> through a user manipulation or the like. In this case, a one-stage partition structure in which the second to fourth partitions <NUM> to <NUM> are accommodated in the first partition <NUM> may be formed.

In this way, the flame leak prevention partition <NUM> according to this embodiment may form a partition structure of four stages in total of, from <NUM> stage to <NUM> stage, through the multi-stage sliding structure, and thus the length of the flame leak prevention partition <NUM> may be variably adjusted. Through this variable flame leak prevention partition structure, in this embodiment, according to the module width of the battery module <NUM>, the flame leak prevention partition <NUM> may be installed in a customized form, so the module compatibility of the exhaust housing <NUM> may be increased.

<FIG> is a diagram for illustrating a pipe unit of the exhaust housing of <FIG>, <FIG> is a diagram for illustrating a pipe connector of the pipe unit of <FIG>, <FIG> are diagrams for illustrating a connection between the pipe connector of <FIG> and a pipe cylinder, <FIG> is a diagram for illustrating the pipe cylinder of the pipe unit of <FIG>, <FIG> is an exploded perspective view showing the pipe cylinder of <FIG>, and <FIG> is a sectional view showing the pipe cylinder of <FIG>.

Referring to <FIG>, the pipe unit <NUM> may be fixed on the at least one flame leak prevention partition <NUM> and communicate with the module case <NUM> and the at least one gas discharge hole <NUM>.

The pipe unit <NUM> may include a plurality of pipe connectors <NUM> and a plurality of pipe cylinders <NUM>.

The plurality of pipe connectors <NUM> may be coupled to a housing cover <NUM>, explained later, and the housing base <NUM>. Specifically, the plurality of pipe connectors <NUM> may be disposed at the upper side of the plurality of gas discharge holes <NUM> of the housing base <NUM>.

Each of the plurality of pipe connectors <NUM> may include a gas discharge hole connection portion <NUM>, an exhaust hole connection portion <NUM> and a cylinder connection portion <NUM>.

The gas discharge hole connection portion <NUM> may be provided at a lower side of the pipe connector <NUM> and be mounted in communication with the plurality of gas discharge holes <NUM> of the housing base <NUM>.

The gas discharge hole connection portion <NUM> may guide the gas inside the module case <NUM> to the inside of the pipe connector <NUM>. Here, according to a preset intake and exhaust directions of the gas, gas discharge hole connection portions <NUM> other than at least one gas discharge hole connection portion <NUM> among the plurality of pipe connectors <NUM> may be sealed using a packing member P.

The packing member P may be made of a rubber material or the like, and the gas discharge hole connection portion <NUM> may be inserted therein to seal the hole or the like of the gas discharge hole connection portion <NUM>.

The exhaust hole connection portion <NUM> may be provided at an upper side of the pipe connector <NUM> and be provided at a side opposite to the gas discharge hole connection portion <NUM>. Among the plurality of pipe connectors <NUM>, at least one exhaust hole connection portion <NUM> may be mounted in communication with an exhaust hole <NUM> of the housing cover <NUM>, explained later.

Here, according to the preset intake and exhaust directions of the gas, exhaust hole connection portions <NUM> other than at least one exhaust hole connection portion <NUM> among the plurality of pipe connectors <NUM> may be sealed using the packing member P.

The cylinder connection portion <NUM> may be provided in a pair. The pair of cylinder connection portions <NUM> may be connected to communicate with one or more cylinder tubes <NUM> of the pipe cylinder <NUM>, explained later, according to the preset intake and exhaust directions of the gas. According to the preset intake and exhaust directions of the gas, a cylinder connection portion <NUM> that is not connected to the cylinder tube <NUM>, explained later, may be sealed using the packing member P.

The plurality of pipe cylinders <NUM> may communicate with the plurality of pipe connectors <NUM> and be fixed on the at least one flame leak prevention partition <NUM>. Specifically, the plurality of pipe cylinders <NUM> may be connected in communication with the cylinder connection portion <NUM>.

The plurality of pipe cylinders <NUM> may include a plurality of cylinder tubes <NUM> and at least one cylinder grid <NUM>.

The plurality of cylinder tubes <NUM> are formed in a predetermined length, and may be coupled with the plurality of pipe connectors <NUM>. Specifically, the plurality of cylinder tubes <NUM> may be connected in communication with the cylinder connection portion <NUM>.

The at least one cylinder grid <NUM> is for connecting the plurality of cylinder tubes <NUM> to each other, and may be mounted between two facing cylinder tubes <NUM>.

The at least one cylinder grid <NUM> has a sectional structure of a grid shape, and may connect two cylinder tubes <NUM> to each other. In addition, the at least one cylinder grid <NUM> may function as a guide for preventing flame leak.

The sealing member <NUM> (see <FIG>) is for sealing the inside of the exhaust housing <NUM>, and may be inserted into and mounted to the sealing member insert groove <NUM> of the housing base <NUM>.

<FIG> is a diagram for illustrating a housing cover of the exhaust housing of <FIG>.

Referring to <FIG>, the housing cover <NUM> covers the pipe unit <NUM> and may be coupled with the housing base <NUM>.

The housing cover <NUM> may include a case fastening hole <NUM> and an exhaust hole <NUM>.

The case fastening hole <NUM> may be provided in plural. The plurality of case fastening holes <NUM> are formed along the edge of the housing cover <NUM> and may be spaced apart from each other by a predetermined distance. The fastening bolts <NUM> of the fastening member <NUM> may penetrate the plurality of case fastening holes <NUM>.

The exhaust hole <NUM> is formed at an upper side of the housing cover <NUM>, and may be connected in communication with the exhaust hole connection portion <NUM> (see <FIG>) of the pipe connector <NUM> (see <FIG>) of the pipe unit <NUM>. The gas flowing along the pipe unit <NUM> may be discharged out of the exhaust housing <NUM> through the exhaust hole <NUM>.

Hereinafter, the gas discharge when a fire occurs due to a fire situation of the battery module <NUM> according to this embodiment will be described in more detail.

<FIG> are diagrams for illustrating gas discharge when a fire occurs due to a fire situation of the battery module of <FIG>.

Referring to <FIG>, when an abnormal situation such as thermal runaway occurs in at least one of the battery cells <NUM> of the battery cell assembly <NUM> of the battery module <NUM>, a fire may occur in at least one battery cell <NUM>. When a fire occurs as above, in order to prevent a larger secondary damage, it is necessary to emit only gas out of the module case <NUM> while preventing the leakage of flame or the like out of the module case <NUM>.

In this embodiment, when the fire situation occurs, it is possible to prevent the flame generated inside the module case <NUM> from being leaked by means of the exhaust housing <NUM>. In addition, the gas G generated inside the module case <NUM> may flow along a exhaust path (indicated by a dotted line in <FIG>) of the pipe unit <NUM> of the exhaust housing <NUM> and then be quickly discharged out of the module case <NUM> through the exhaust hole <NUM> (see <FIG>) of the housing cover <NUM>.

As such, the battery module <NUM> according to this embodiment may discharge the gas G out of the module case <NUM> more quickly while suppressing the emission of the flame by means of the exhaust housing <NUM> when the fire situation occurs, thereby minimizing a secondary damage that may be caused by the fire.

Hereinafter, exhaust housings according to various embodiments of the present disclosure will be described in more detail.

<FIG> are diagrams for illustrating exhaust housings according to various embodiments of the present disclosure.

Referring to <FIG>, in the battery module <NUM>, when the explosive force is small, for example, when the capacity of the battery cells is relatively small, the explosion may be suppressed even with low rigidity, so a manufacturer or the like may reduce the number of flame leak prevention partitions <NUM> in the exhaust housing <NUM>. Accordingly, the battery module <NUM> according to this embodiment may secure cost competitiveness by reducing costs as much as the reduced number of the flame leak prevention partitions <NUM>.

Referring to <FIG>, in the battery module <NUM>, when the explosive force is large, for example, when the capacity of the battery cells is relatively large, high rigidity is required, so the manufacturer or the like may further increase the number of flame leak prevention partitions <NUM> in the exhaust housing <NUM>.

Referring to <FIG>, in the battery module <NUM>, when the width of the battery module <NUM> is narrow, the manufacturer or the like may reduce the length of the flame leak prevention partition <NUM> of the exhaust housing <NUM>. That is, the flame leak prevention partition <NUM> may be modified to a three-stage partition type. This is only an example, and it is also possible to modify the flame leak prevention partition <NUM> to a two-stage or one-stage partition type, and it is also possible to increase the number of partitions to five or more according to the design or the like.

As such, in this embodiment, in the exhaust housing <NUM>, <NUM>, <NUM>, <NUM>, the number of flame leak prevention partitions <NUM>, <NUM>, <NUM>, <NUM> of the exhaust housings <NUM>, <NUM>, <NUM>, <NUM> may be reduced according to the width size or rigidity of the battery module <NUM>, <NUM>, <NUM>, <NUM>, or the length thereof may be varied. Accordingly, it is possible to implement an exhaust housing structure with high extensibility and compatibility.

<FIG> is a diagram for illustrating a battery pack according to an embodiment of the present disclosure, and <FIG> is a diagram for illustrating a vehicle according to an embodiment of the present disclosure.

Referring to <FIG>, a battery pack <NUM> may include at least one battery module <NUM> according to the former embodiment and a pack case <NUM> for packaging the at least one battery module <NUM>. Moreover, in addition to the battery module <NUM>, the battery modules <NUM> to <NUM> of the former embodiments may also be included.

The battery pack <NUM> may be provided to a vehicle as a fuel source of a vehicle V. As an example, the battery pack <NUM> may be provided to an electric vehicle, a hybrid electric vehicle, and various other-type vehicles V capable of using the battery pack <NUM> as a fuel source.

In addition, the battery pack <NUM> may be provided in other devices, instruments or facilities such as an energy storage system using a secondary battery, in addition to the vehicle V.

As described above, the battery pack <NUM> of this embodiment and devices, instruments or facilities such as a vehicle, which have the battery pack <NUM>, include the battery module <NUM> to <NUM> as described above, and thus it is possible to implement a battery pack <NUM> having all the advantages of the battery module <NUM> to <NUM> described above, or devices, instruments, facilities or the like such as a vehicle V, which have the battery pack <NUM>.

According to various embodiments as described above, it is possible to provide a battery module <NUM>, <NUM>, <NUM>, <NUM>, which may prevent a flame leak to the outside of a module case <NUM> and also discharge an exhaust gas G out of the module case <NUM> when a fire situation occurs due to thermal runaway of battery cells <NUM>, and a battery pack <NUM> and a vehicle V including the battery module <NUM>, <NUM>, <NUM>, <NUM>.

Claim 1:
A battery module (<NUM>), comprising:
at least one battery cell assembly (<NUM>) including at least one battery cell (<NUM>);
a module case (<NUM>) configured to accommodate the at least one battery cell assembly (<NUM>); and
an exhaust housing (<NUM>) coupled to the module case (<NUM>) to cover the at least one battery cell assembly (<NUM>), the exhaust housing (<NUM>) having at least one gas discharge hole (<NUM>) for discharging a gas inside the module case (<NUM>) and a plurality of flame leak prevention partitions (<NUM>) for variably adjusting a length thereof,
characterized in that the exhaust housing (<NUM>) includes:
a housing base (<NUM>) configured to cover an upper side of the module case (<NUM>);
the plurality of flame leak prevention partitions (<NUM>) fixed to the housing base (<NUM>);
a pipe unit (<NUM>) fixed on the plurality of flame leak prevention partitions (<NUM>) and configured to communicate with the module case (<NUM>) and the at least one gas discharge hole (<NUM>); and
a housing cover (<NUM>) configured to cover the pipe unit (<NUM>) and coupled to the housing base (<NUM>), and
wherein the plurality of flame leak prevention partitions (<NUM>) are configured to variably perform multi-stage sliding along a width direction of the housing base (<NUM>).