Patent Description:
A battery module including submodules with battery cells has been developed and applied as an eco-friendly power source for an electric automobile such as a hybrid vehicle. A secondary battery may be charged and discharged differently from primary batteries, and has attracted attention as a power source of various mobile devices and electric vehicles. For example, a battery module may be formed by connecting a plurality of secondary batteries using a high energy density non-aqueous electrolyte, and the battery module may be used as a power source for an electric vehicle. For example, <CIT> relates to a battery module including first and second cell block assemblies that include a battery cell stack and are arranged along a direction perpendicular to the stacking direction of the battery cell stack. A module frame that houses the first and second cell block assemblies and is opened in a front and rear direction. Further, a cooling plate arranged below the bottom portion of the module frame, wherein a flow path through which refrigerant flows is formed in the cooling plate, and the flow path is formed in a direction parallel to the arrangement direction of the first and second cell block assemblies. <CIT> relates to battery module including a module housing including a first plate in which one side is open, a second plate coupled with the first plate to form an internal space, and a partition member disposed across the internal space to couple the first plate with the second plate, and a battery cell stack disposed in the internal space, in which a plurality of battery cells are stacked. <CIT> relates to battery device including a plurality of cell assemblies each including a plurality of battery cells, a housing including an accommodation space in which the plurality of cell assemblies are accommodated, and a cooling plate installed in the housing to cool the plurality of cell assemblies. The cooling plate includes a plurality of seating portions on which the cell assemblies are seated, respectively, and a heat transfer delay portion disposed between the plurality of seating portions and preventing or reducing heat transfer between the seating portions adjacent to each other.

In principle, when a temperature of a secondary battery is higher than an appropriate temperature, performance of the secondary battery may deteriorate, and in severe cases, there may be a risk of explosion or ignition. In particular, to configure a high capacity and large-area battery module, the number of required battery cells may increase, but as a plurality of battery cells are concentrated in a small space, temperature of the battery module may increase rapidly.

Therefore, to stably charge and discharge a high-capacity battery module including a plurality of battery cells, a cooling structure for efficiently controlling a temperature of the battery module may be necessary.

An example embodiment of the present disclosure is to provide a cooling plate for swiftly and effectively cooling a battery module having high capacity and a battery module including the same.

An example embodiment of the present disclosure is to provide a cooling plate having a structure corresponding to a structure in which a plurality of sub-modules are coupled, and a battery module including the same.

According to an example embodiment of the present disclosure, an eco-friendly power source, such as a battery module for a transportation vehicle, includes a first sub-module and a second sub-module, each of the first and second sub-modules including a plurality of battery cells; a connection member having a first side coupled to the first sub-module and a second side coupled to the second sub-module, the second side being opposite to the first side; and a cooling plate configured to cool the first and second sub-modules.

The battery module includes a lower cover supporting the first sub-module and the second sub-module. The cooling plate couples to the lower cover and forming a flow path through which a refrigerant can flow, wherein at least a portion of the flow path is disposed to oppose the connection member with the lower cover interposed therebetween.

The flow path may include a first flow path disposed below the first sub-module; a second flow path disposed below the second sub-module; and a third flow path connecting the first flow path to the second flow path, wherein at least a portion of the third flow path is disposed to oppose the connection member with the lower cover interposed therebetween.

The cooling plate includes a guide disposed in the flow path and configured to guide a flow of the refrigerant.

The guide may include a plurality of guide protrusions protruding in a direction toward the lower cover and in contact with the lower cover.

The first sub-module and the second sub-module may be disposed to oppose each other in a first direction, and at least one of the plurality of guide protrusions includes a flat portion inclined with respect to the first direction; and curved portions disposed on both ends of the flat portion.

The first sub-module and the second sub-module may be disposed to oppose each other in a first direction, and the guide may include one or more guide protrusion groups consisting of a plurality of guide protrusions arranged in a second direction different from the first direction.

The one or more guide protrusion groups may include a first guide protrusion group and a second guide protrusion group, the plurality of guide protrusions included in the first guide protrusion group may be spaced apart from each other by a first distance, one of the plurality of guide protrusions included in the first guide protrusion group is spaced apart from the second guide protrusion group with a second distance therebetween, and the first distance may be less than or equal to the second distance.

The first flow path may communicate with the second flow path through the third flow path.

The connection member is coupled to one surface of the lower cover, and the cooling plate may be coupled to the other surface opposite to the one surface of the lower cover.

The lower cover may include a fastening portion fastened to the connection member, and the cooling plate may include an avoidance portion preventing contact between the fastening portion and the refrigerant.

The avoidance portion may have an opening shape penetrating through the cooling plate between a first flow path disposed below the first sub-module and a second flow path disposed below the second sub-module.

The flow path may include a first flow path forming a first path through which the refrigerant can flow; and a second flow path forming a second path partitioned from the first path, and a portion of the first flow path and a portion of the second flow path are disposed spaced apart from each other with the avoidance portion interposed therebetween.

A plurality of the avoidance portions may be disposed in a length direction of the connection member, and at least one of the first flow path and the second flow path may include a first sub-flow path and a second sub-flow path spaced apart from each other with at least one of the plurality of avoidance portions interposed therebetween.

A heat dissipation member may be disposed on the one surface of the lower cover.

According to an example embodiment of the present disclosure, a battery module includes a first sub-module and a second sub-module including a plurality of battery cells, respectively; a lower cover supporting the first sub-module and the second sub-module; a connection member disposed between the first sub-module and the second sub-module; and a cooling plate coupled to the lower cover and forming a flow path through which a refrigerant can flow, wherein the lower cover includes a fastening portion fastened to the connection member, and the cooling plate includes an avoidance portion exposing the fastening portion.

The cooling plate may include a plurality of avoidance portions, the first sub-module and the second sub-module may be disposed to oppose each other in a first direction with the connection member interposed therebetween, and the plurality of avoidance portions may be spaced apart from each other in a second direction perpendicular to the first direction.

The cooling plate may include a flow path forming a flow path through which a refrigerant can flow, and at least a portion of the flow path may be disposed between the plurality of avoidance portions.

The flow path may include a first flow path for cooling the first sub-module; a second flow path for cooling the second sub-module; and a third flow path connecting the first flow path to the second flow path, and at least a portion of the third flow path is disposed between the plurality of avoidance portions.

The battery module may further include a fastening member penetrating through the fastening portion and fastened to the connection member.

According to another aspect of the present disclosure, a battery module includes a first sub-module including a first plurality of battery cells; a second sub-module including a second plurality of battery cells, a connection member having a first side coupled to the first sub-module and a second side coupled to the second sub-module, the second side being opposite to the first side; and a cooling plate configured to cool the first and second sub-modules.

It is to be understood that the terms or words used in this description and the following claims must not be construed to have meanings which are general or may be found in a dictionary.

In the drawings, same elements will be indicated by same reference numerals. Also, redundant descriptions and detailed descriptions of known functions and elements which may unnecessarily make the gist of the present disclosure obscure will not be provided. In the accompanying drawings, a portion of elements may be exaggerated, omitted or briefly illustrated, and the sizes of the elements do not necessarily reflect the actual sizes of these elements.

The terms, "include," "comprise," "is configured to," etc. of the description are used to indicate the presence of features, numbers, steps, operations, elements, portions or combination thereof, and do not exclude the possibilities of combination or addition of one or more features, numbers, steps, operations, elements, portions or combination thereof.

In example embodiments, terms such as an upper side, an upper portion, a lower side, a lower portion, a side surface, a front surface, a rear surface, or the like, are represented based on the directions in the drawings, and may be used differently if the direction of an element is changed.

The terms "first," "second," and the like may be used to distinguish one element from the other, and may not limit a sequence and/or an importance, or others, in relation to the elements.

<FIG> is a perspective diagram illustrating a battery module according to an example embodiment. <FIG> is an exploded perspective diagram illustrating a battery module according to an example embodiment. <FIG> is a diagram illustrating a state in which a cooling plate is coupled to a lower cover.

Referring to <FIG>, the battery module <NUM> includes a plurality of sub-modules <NUM>, a connection member <NUM> disposed between the sub-modules <NUM>, a lower cover <NUM> and an upper cover <NUM>. The lower cover <NUM> and the upper cover <NUM> may support the sub-modules <NUM>. The battery module <NUM> may further include a cooling plate <NUM> for cooling the battery module <NUM>.

In the embodiment of <FIG> the plurality of sub-modules <NUM> , for example, include a first sub-module 100a and a second sub-module 100b arranged adjacent to each other in a first direction, e.g., an X-axis direction, with the connection member <NUM> disposed between them. The first sub-module 100a and the second sub-module 100b may be assembled together and may form at least a portion of one battery module <NUM>.

One or more connection members <NUM> may be disposed between two of the plurality of sub-modules <NUM>. For example, as illustrated in <FIG>, a connection member <NUM> is disposed between the first sub-module 100a and the second sub-module 100b disposed side by side in the first direction (X-axis direction).

The connection member <NUM> may have a shape of a partitioner extending in a second direction (Y-axis direction) perpendicular to the first direction (X-axis direction). The connection member <NUM> may be formed of a material having a predetermined level of rigidity so as to structurally support the first sub-module 100a and the second sub-module 100b. For example, the connection member <NUM> may include a metal material such as aluminum or stainless steel.

The first sub-module 100a and the second sub-module 100b may be coupled to opposite sides of the connection member <NUM>, respectively. For example, the first sub-module 100a may be fastened to at least one portion of a first side of the connection member <NUM>, and the second sub-module 100b may be fastened to at least one portion of a second side of the connection member <NUM>. The second side of the connection member <NUM> may be opposite to the first side of the connection member <NUM>. Accordingly, the first sub-module 100a and the second sub-module 100b may be fixed to each other via the connection member <NUM>.

In the battery module <NUM> including a plurality of sub-modules <NUM>, the connection member <NUM> may work as a reference point for assembling the sub-modules <NUM>. That is, the connection member <NUM> may partition a space in the battery module <NUM> in which each sub module <NUM> is accommodated, and may guide a position in which the sub module <NUM> is disposed.

The battery module <NUM> may include lower cover <NUM> and upper cover <NUM> for supporting the plurality of sub-modules <NUM>. For example, referring to <FIG>, the integrally formed lower cover <NUM> may be disposed to cover the lower surfaces of the plurality of sub-modules <NUM>, and the integrally formed upper cover <NUM> may be disposed to cover the upper surfaces of the plurality of sub-modules <NUM>. The lower cover <NUM> and the upper cover <NUM> may be integrally formed to stably support the plurality of sub-modules <NUM>.

The battery module <NUM> includes a cooling plate <NUM> for cooling the battery modules. For example, referring to <FIG>, the cooling plate <NUM> is coupled to the lower cover <NUM> and may absorb thermal energy generated by the sub-modules 100a and 100b.

The cooling plate <NUM> may include a cooling frame <NUM> forming a flow path <NUM>. The cooling frame <NUM> may form a structure of the cooling plate <NUM> and may be combined with the lower cover <NUM> and may form a flow path <NUM> which may be a path through which a refrigerant can flow. Any suitable coupling method may be used between the cooling frame <NUM> and the lower cover <NUM>, such as, for example, welding, brazing, roll-bonding, thermal fusion, filler bonding, friction welding, or a physical fastening method through a separate fastening member. These methods may be applied alone or in combination with each other.

The flow path <NUM> may be formed on one surface of the cooling frame <NUM>. For example, referring to <FIG>, the cooling frame <NUM> may have a structure in which at least a portion thereof is recessed in a downward direction (e.g., in a negative Z-axis direction), and as the cooling frame <NUM> is coupled to the lower cover <NUM>, a flow path <NUM> through which refrigerant can flow may be formed in the space defined between the recessed portion of the cooling frame <NUM> and the lower cover <NUM>. However, <FIG> only illustrates an example shape of the flow path <NUM>, and the flow path <NUM> may be formed in the cooling frame <NUM>.

In <FIG>, a portion of the cooling plate <NUM> may be shaded, which is only for distinguishing a portion in which the refrigerant may flow and a portion in which the refrigerant does not flow in the flow path <NUM>. The shading does not indicate that the shaded portion and the non-shaded portion are separate members. For example, the cooling plate <NUM> in <FIG> may have an integrated cooling frame <NUM> and a flow path <NUM> formed on at least a portion of the cooling frame <NUM>. The shading is applied in <FIG> for the same reasons as indicated above for <FIG>.

Referring to <FIG>, the refrigerant flowing through the flow path <NUM> may be any suitable cooling fluid. The refrigerant flowing through the flow path <NUM> may be, for example, cooling water. The refrigerant flowing into the cooling plate <NUM> may absorb thermal energy generated in the first and second sub-modules 100a and 100b for cooling the first and second sub-modules 100a and 100b.

The cooling plate <NUM> may include a guide <NUM> for guiding the flow of the refrigerant. For example, referring to <FIG>, the guide <NUM> may be formed such that a portion of the cooling frame <NUM> may protrude in a direction toward the lower cover <NUM> in the flow path <NUM>. When the cooling frame <NUM> is coupled to the lower cover <NUM>, the guide <NUM> may be in contact with the lower cover <NUM>. Accordingly, the refrigerant may not pass through the guide <NUM> and may flow along the circumference of the guide <NUM>. Accordingly, the flow path or flow rate of the refrigerant may be determined by appropriately designing the shape of the guide <NUM>.

In the cooling plate <NUM> according to the example embodiments, the shape of the guide <NUM> may be configured in various manners. For example, as illustrated in <FIG>, at least a portion of the guide <NUM> may have a shape of a protrusion extending in a direction oblique with respect to the first direction (X-axis direction) in which the first sub-module 100a and the second sub-module 100b oppose each other. However, the shape of the guide <NUM> is not limited to the example illustrated in the drawings.

Depending on the shape of the guide <NUM>, the flow rate, cooling efficiency, and pressure drop of the refrigerant flowing through the flow path <NUM> may vary. The guide <NUM> may, for example, have a shape that optimizes the flow of the cooling fluid for enhance heat removal. A specific shape of the guide <NUM> will be described later.

Referring to <FIG> and <FIG>, the cooling frame <NUM> or the lower cover <NUM> may include a plurality of ports <NUM> through which refrigerant flows in and out. For example, the lower cover <NUM> may include a first port <NUM> and a second port <NUM> communicating with the flow path <NUM> of the cooling plate <NUM>. Here, the first port <NUM> may be an inlet for the refrigerant, and the second port <NUM> may be an outlet through which the refrigerant may be discharged. That is, the refrigerant may flow into the first port <NUM>, may flow along the flow path <NUM> formed by the cooling frame <NUM>, and may be discharged to the outside of the battery module <NUM> through the second port <NUM>.

The positioning of the first port <NUM> and the second port <NUM> may vary. <FIG> illustrates a configuration according to which the first and second ports <NUM> and <NUM> are disposed on opposite ends of the lower cover <NUM>. Alternatively, the first port <NUM> and the second port <NUM> may be disposed in the cooling frame <NUM>.

In the battery module, a plurality of ports <NUM> may be disposed. For example, as illustrated in <FIG>, the battery module <NUM> may include a single first port <NUM> and a single second port <NUM>, and in this case, the refrigerant flowing into the first port <NUM> may cool both the first sub-module 100a and the second sub-module 100b.

Alternatively, a plurality of first ports <NUM> and a plurality of second ports <NUM> may be disposed such that independent cooling flow paths may be formed for each of the sub-modules 100a and 100b.

In the battery module <NUM> according to the invention both the connection member <NUM> and the cooling plate <NUM> are coupled to the lower cover <NUM>. For example, the connection member <NUM> is coupled to one surface of the lower cover <NUM> and the cooling plate <NUM> is coupled to the other surface of the lower cover <NUM>.

The cooling plate <NUM> may include one or more avoidance portions <NUM> not to interfere with the coupling structure of the connection member <NUM> and the lower cover <NUM>. Referring to <FIG> and <FIG>, the avoidance portion <NUM> may be an opening penetrating through the cooling frame <NUM>.

One or more avoidance portions <NUM> may be provided to correspond to positions in which the connection member <NUM> and the lower cover <NUM> are coupled to each other. For example, referring to <FIG>, the lower cover <NUM> may include a fastening portion <NUM> coupled to the connection member <NUM>, and the fastening portion <NUM> may be exposed in a downward direction (e.g., a negative Z-axis direction) of the battery module <NUM> through the avoidance portion <NUM>.

The battery module <NUM> may include a fastening member <NUM> for coupling the lower cover <NUM> to the connection member <NUM>. The fastening portion <NUM> of the lower cover <NUM> may have a hole shape into which the fastening member <NUM> may be inserted. The fastening member <NUM> may pass through the fastening portion <NUM> of the lower cover <NUM> and may be fastened to the connection member <NUM>, and the plurality of fastening members <NUM> may be connected to the cooling frame <NUM> corresponding to the position to which the avoidance portion <NUM> is fastened.

The avoidance portion <NUM> may be disposed to oppose the connection member <NUM> with the lower cover <NUM> therebetween. The fastening portion <NUM> of the lower cover <NUM> may be exposed through the avoidance portion <NUM>, and the fastening member <NUM> may be inserted into the exposed fastening portion <NUM> and may be coupled to the connection member <NUM>.

At least a portion of the flow path <NUM> may be formed between the plurality of avoidance portions <NUM>. That is, a cooling flow path may be formed between the avoidance portions <NUM>, and accordingly, at least a portion of the refrigerant flowing into the cooling plate <NUM> may flow between the plurality of avoidance portions <NUM>.

In the cooling plate <NUM>, the flow path <NUM> may be configured to cover the entirety of the plurality of sub-modules <NUM>. For example, referring to <FIG>, the flow path <NUM> of the cooling plate <NUM> may have a cooling region opposing the lower surface of the first sub-module 100a and the lower surface of the second sub-module 100b to cool both the first sub-module 100a and the second sub-module 100b. That is, the cooling plate <NUM> of the battery module <NUM> may be configured to have an integrated cooling structure for cooling the entirety of the plurality of sub-modules <NUM>.

To improve cooling efficiency, a heat dissipation member <NUM> may be disposed between the lower cover <NUM> and the plurality of sub-modules <NUM>. One surface of the heat dissipation member <NUM> may be disposed to be in contact with the sub-module <NUM> and the other surface opposite to the one surface may be in contact with the lower cover <NUM>. The heat dissipation member <NUM> may be provided with a thermal adhesive. The heat dissipation member <NUM> may fill a space between the sub module <NUM> and the lower cover <NUM> such that heat transfer by conduction may be actively performed. Accordingly, heat dissipation efficiency of the battery module <NUM> may be increased.

The battery module <NUM> may include an upper cover <NUM> covering the upper portion of the sub-module <NUM>. The upper cover <NUM> may be integrally formed to simultaneously support the plurality of sub-modules <NUM>.

The upper cover <NUM> may have an opening <NUM> to expose a terminal portion of the sub-module <NUM> (e.g., <NUM> in <FIG>) or a portion of the sensing module of the sub-module <NUM>.

Each sub-module <NUM> includes a plurality of battery cells and may be configured to store or discharge electrical energy.

In the battery module <NUM>, a plurality of sub-modules <NUM> may be electrically connected to each other and may output design power values required for the battery module. For example, the two sub-modules <NUM> opposing each other with the connection member <NUM> interposed therebetween may be connected to each other in series or in parallel through terminal portions (e.g., <NUM> in <FIG>).

Conversely, in the battery module <NUM>, the plurality of sub-modules <NUM> may be electrically isolated from each other. For example, the two sub-modules <NUM> opposing each other with the connection member <NUM> interposed therebetween may be electrically separated from each other, and the terminal portion of each sub-module <NUM> (e.g., <NUM> in <FIG>) may be configured to be electrically connected to another neighboring battery module <NUM>.

Hereinafter, sub-modules according to example embodiments will be described with reference to <FIG>.

<FIG> is an exploded perspective diagram illustrating a sub-module <NUM> included in a battery module <NUM> according to an example embodiment. Since the sub-module <NUM> described with reference to <FIG> may correspond to one of the first sub-module 100a and the second sub-module 100b previously described with reference to <FIG>, overlapping descriptions may be omitted.

The battery module <NUM> may include a plurality of sub-modules <NUM>. At least one of the plurality of sub-modules <NUM> included in the battery module <NUM> may include a cell assembly CA and a plurality of protective covers <NUM> and <NUM> protecting the cell assembly CA. Here, the protective covers <NUM> and <NUM> may include an end cover <NUM> covering at least one side of the cell assembly CA and one or more side covers <NUM>.

The cell assembly CA may include a cell stack <NUM> including battery cells <NUM> stacked in one direction (e.g., the Y-axis direction in <FIG>), 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 a plurality of battery cells <NUM> electrically connected to each other. In one cell stack <NUM>, the plurality of battery cells <NUM> may be stacked in one direction (e.g., the Y-axis direction). In the description below, the stacking direction of the battery cells <NUM> included in the cell stack <NUM> may be referred to as a "second direction" or a "cell stacking direction.

The busbar assembly <NUM> may include a plurality of busbars <NUM> electrically connecting the battery cells <NUM> of the cell stack <NUM> to each other and a support frame supporting the busbars <NUM>.

The busbar <NUM> may be formed of a conductive material and may electrically connect the plurality of battery cells <NUM> to each other. The busbar <NUM> may be electrically connected to the battery cell <NUM> while being fixed to the support frame.

The support frame may support the busbar <NUM> to be stably connected to the battery cell <NUM>. The support frame may include a non-conductive material (e.g., plastic) having a predetermined stiffness and may structurally support the plurality of busbars <NUM>.

The support frame may oppose at least one side of the cell stack <NUM>. For example, referring to <FIG>, the support frame may include a busbar frame <NUM> opposing the cell stack <NUM> in a first direction (X-axis direction) and supporting the busbar <NUM>, and a connection frame <NUM> opposing the cell stack <NUM> in the third direction (Z-axis direction) and connected to the busbar frame <NUM>. Here, the second direction may be perpendicular to the first direction, and the third direction may be perpendicular to both the first and second directions.

A sensing module <NUM> for sensing the electrical and thermal states of the battery cells <NUM> may be disposed on the connection frame <NUM>. Voltage information or temperature information sensed by the sensing module <NUM> may be transmitted to the outside of the sub-module <NUM> and may be used to control the battery module <NUM>.

The cell assembly CA may include the insulating cover <NUM> covering at least one surface of the busbar assembly <NUM>. The insulating cover <NUM> may include a non-conductive material and may prevent the busbar <NUM> of the busbar assembly <NUM> from being unintentionally shorted with other components.

An end cover <NUM> may be disposed on the outermost side of one side of the sub module <NUM>. The end cover <NUM> may include a rigid material (e.g., a metal material such as aluminum) and may protect the cell assembly CA from external impact. In a state in which the sub-module <NUM> is coupled to the connection member (e.g., <NUM> in <FIG>) and the lower cover (e.g., <NUM> in <FIG>), the end cover <NUM> may be spaced apart from the connection member <NUM> and may be disposed on one of the edges of the lower cover <NUM>.

In example embodiments, a plurality of insulating covers <NUM> of the cell assembly CA may be provided. For example, the sub module <NUM> may include a first insulating cover <NUM> electrically separating the connecting member <NUM> and the busbar assembly <NUM> from each other, and a second insulating cover <NUM> electrically separating the end cover <NUM> and the busbar assembly <NUM> from each other.

The first insulating cover <NUM> may be disposed between the connection member <NUM> and the busbar <NUM> and may electrically separate the components from each other. Similarly, the second insulating cover <NUM> may be disposed between the end cover <NUM> and the busbar <NUM> and may electrically separate the components from each other.

The insulating cover <NUM> may be coupled to the busbar assembly <NUM>. For example, each of the first insulating cover <NUM> and the second insulating cover <NUM> may be inserted into and fixed to the busbar frame <NUM>. Alternatively, the insulating cover <NUM> may be fixed to the busbar frame <NUM> through a fastening member.

The sub module <NUM> may include a side cover <NUM> opposing at least one side of the cell stack <NUM>.

A pair of side covers <NUM> may be provided to cover different surfaces of the cell stack <NUM>. The pair of side covers <NUM> may be coupled to the end cover <NUM> and the connection member <NUM>, may form a side surface of the sub module <NUM> and may protect the cell stack <NUM> from an external environment.

The side cover <NUM> may oppose the cell stack <NUM> in a different direction from the end cover <NUM>. For example, as illustrated in <FIG>, the side cover <NUM> may be disposed to oppose the cell stack <NUM> in the second direction (Y-axis direction), and the end cover <NUM> may be disposed to oppose the cell stack <NUM> in the first direction (X-axis direction) with the busbar assembly <NUM> and the second insulating cover <NUM> interposed therebetween. Accordingly, the end cover <NUM>, the pair of side covers <NUM>, and the first insulating cover <NUM> may form four surfaces of the sub module <NUM>.

In the side cover <NUM>, the end cover <NUM> may be coupled to one end, and the connection member <NUM> of the battery module <NUM> may be coupled to the other end opposite to one side. To increase coupling strength, the busbar assembly <NUM> may also be coupled to the side cover <NUM>.

The side cover <NUM> may further include a connection portion <NUM> which may be structurally connected to an external component of the battery module <NUM>. For example, referring to <FIG>, the connection portion <NUM> may have a structure protruding from the surface of the side cover <NUM> in a second direction (Y-axis direction). The battery module <NUM> may be coupled to an external component (e.g., a battery pack housing in which the plurality of battery modules <NUM> are accommodated) through the connection portion <NUM> of the side cover <NUM>.

The lower surface of the sub-module <NUM> may be configured such that the cell stack <NUM> may be exposed. For example, the sub-module <NUM> may not have a cover member on a lower surface thereof, and accordingly, the cell stack <NUM> may be in direct contact with an external component of the sub-module <NUM> (e.g., the lower cover <NUM> or the heat dissipation member <NUM> of the battery module <NUM> illustrated in <FIG>). Accordingly, heat may be smoothly discharged from the cell stack <NUM> toward the lower portion of the sub-module <NUM>, such that heat dissipation efficiency of the sub-module <NUM> may be increased.

In the sub-module <NUM>, an end cover <NUM> may be disposed in an outermost portion of one side and a first insulating cover <NUM> may be disposed in an outermost portion of the other side. That is, one sub-module <NUM> may include a first surface on which the insulating cover <NUM> is disposed and a second surface on which the end cover <NUM> is disposed. For example, referring to <FIG>, the first surface of one sub-module <NUM> may be closed with an insulating cover <NUM>, and the second surface opposite to the first surface may be closed with an end cover <NUM>.

The two sub-modules <NUM> disposed to oppose each other with the connection member <NUM> interposed therebetween may be disposed such that the first surfaces thereof may oppose the connection member <NUM>. For example, the first sub-module 100a may be coupled to the connection member <NUM> such that the first surface on which the insulating cover <NUM> is disposed may oppose the connection member <NUM>, and the second sub-module 100b may be coupled to the connection member <NUM> such that the first surface on which the insulating cover <NUM> is disposed may oppose the connection member <NUM>. By the connection structure, in the battery module <NUM> in which the first sub-module 100a and the second sub-module 100b are connected to each other, the end covers <NUM> of each sub-module <NUM> may form the front and rear outer surfaces, and the side covers <NUM> coupled to the end cover <NUM> may form the side outer surfaces.

Hereinafter, the flow path formed by the cooling plate will be described with reference to <FIG>.

<FIG> is a diagram illustrating cooling plate <NUM> according to an example embodiment, viewed from above. <FIG> is an enlarged diagram illustrating a portion of the cooling plate <NUM> in <FIG> according to an example embodiment. <FIG> is a diagram illustrating an example in which a shape of an avoidance portion <NUM> is partially changed in the cooling plate <NUM> in <FIG>. Since the cooling plate <NUM> described with reference to <FIG> and <FIG> may be similar to the cooling plate <NUM> previously described with reference to <FIG>, overlapping descriptions may not be provided.

The cooling plate <NUM> may be configured to cool the entirety of the plurality of sub-modules (e.g., <NUM> in <FIG>) included in the battery module (e.g., <NUM> in <FIG> and <FIG>). For example, the cooling plate <NUM> may cool first and second regions A and C corresponding to the first sub-module 100a and the second sub-module 100b, respectively, and a third region B corresponding to a portion in which a connecting member (e.g., <NUM> in <FIG> and <FIG>) is disposed.

The flow path of the cooling plate <NUM> may include a first flow path <NUM> for cooling the first region A, a second flow path <NUM> for cooling the second region C, and third flow path <NUM> for cooling the third region B. Referring to <FIG>, the first flow path <NUM>, the third flow path <NUM>, and the second flow path <NUM> may be arranged in a direction parallel to the first direction (e.g., the X-axis direction) in which the first sub-module 100a and the second sub-module 100b are arranged.

The first flow path <NUM> of the cooling plate <NUM> may communicate with the second flow path <NUM> through the third flow path <NUM>.

The refrigerant flowing from the first port <NUM> may cool the first sub-module 100a while flowing along the first flow path <NUM>. The refrigerant passing through the first flow path <NUM> may flow to the second flow path <NUM> through the third flow path <NUM>. The refrigerant may cool the second sub-module 100b while flowing along the second flow path <NUM> and may exit through the second port <NUM>.

The cooling frame <NUM> forming the first to third flow paths <NUM>, <NUM>, and <NUM> may be integrally formed, and accordingly, the cooling plate <NUM> having a structurally simple and stable cooling performance may be implemented.

Guide <NUM> may be disposed in the first flow path <NUM> and the second flow path <NUM>. The guide <NUM> may guide the flow of the refrigerant.

The guide <NUM> may include a plurality of guide protrusions 630a and 630b arranged in a predetermined pattern. Here, the pattern formed by the guide protrusions 630a and 630b may be varied depending on the cooling performance requirements of the battery module <NUM>. For example, referring to <FIG> and <FIG>, the cooling plate <NUM> may include a plurality of guide protrusions 630a and 630b forming an oblique pattern with respect to a first direction (X-axis direction) such that the refrigerant which flow in may spread swiftly and widely. The refrigerant flowing in through the first port <NUM> may spread swiftly and evenly to the first flow path <NUM> by the guide protrusions 630a disposed in an oblique pattern in the first flow path <NUM>. Accordingly, a decrease of pressure may be prevented while the refrigerant flows through the flow path and may secure high cooling performance.

Referring to <FIG>, the structure and arrangement of the guide protrusions will be described in detail.

At least a portion of the plurality of guide protrusions may be arranged in one direction and may form a protrusion group. For example, the guide <NUM> may include a guide protrusion groups <NUM>, <NUM>, <NUM>, and <NUM>, a plurality of groups of a plurality of guide protrusions 634a, 634b, or the like, arranged in an oblique direction with respect to one edge of the cooling frame <NUM>.

In the flow path <NUM>, a plurality of guide protrusion groups <NUM>, <NUM>, <NUM>, and <NUM> may be formed. Referring to <FIG>, the guide <NUM> may include a plurality of guide protrusion groups <NUM>, <NUM>, <NUM>, and <NUM>, each having a different number of guide protrusions. For example, the first guide protrusion group <NUM> may include a guide protrusion, the second guide protrusion group <NUM> may include two guide protrusions, and the third guide protrusion group <NUM> may include three guide protrusions.

The guide protrusions included in one of the groups of guide protrusions may have different shapes. For example, by including the fifth guide protrusion group <NUM>, a portion of guide protrusions 635a may have a circular shape, and the other portion of the guide protrusions 635b may have curved ends and a flat central portion.

The guide protrusions included in a group of guide protrusions may be spaced apart from each other in one direction. For example, the guide protrusions 634a, 634b, or the like, of the fourth guide protrusion group <NUM> may be spaced apart to have a first distance d1 therebetween, and may be disposed in the fourth direction having a predetermined angle (a) with the first direction (X-axis direction). Here, the predetermined angle may be an acute angle.

One of the guide protrusion groups may be spaced apart from another guide protrusion group with a predetermined distance therebetween. For example, referring to <FIG>, the guide protrusion 634a included in the fourth guide protrusion group <NUM> and the guide protrusion 625b included in the fifth guide protrusion group <NUM> may be spaced apart from each other to have a second distance d2 therebetween.

In the arrangement of the guide protrusions, the first distance d1 may be equal to or smaller than the second distance d2. When the first distance d1 is smaller than the second distance d2, the refrigerant may smoothly flow in the fourth direction.

At least one of the plurality of guide protrusions may include a flat portion FP having a surface parallel to the fourth direction and a curved portion CP disposed on both ends of the flat portion FP. For example, referring to the partially enlarged diagram in <FIG>, one of the guide protrusions may include a pair of flat portions FP having an inclination with respect to a first direction (X-axis direction) and a curved portion CP connecting the pair of flat portions FP to each other. In this case, the plurality of guide protrusions included in one of the guide protrusion groups may be arranged such that the curved portions CP may oppose each other. Due to this arrangement structure, a decrease of pressure may be prevented while the refrigerant flows between the plurality of guide protrusions, and an effect of facilitating the diffusion of the refrigerant may be obtained.

Similarly to the first flow path <NUM>, a plurality of guides <NUM> may be disposed in the second flow path <NUM> as well. The guide <NUM> disposed on the second flow path <NUM> may have a pattern similar to that of the guide <NUM> disposed on the first flow path <NUM>. For example, a plurality of guide protrusions 630b forming a pattern in a direction parallel to the fourth direction described above may be formed in the second flow path <NUM>.

Referring to <FIG>, when it is assumed that the first region A or the second region C has a substantially rectangular flat shape, the fourth direction, which is the pattern direction of the guide, may be substantially parallel to a diagonal line connecting the lower left corner (hereinafter referred to as a first corner) and the upper right corner (hereinafter referred to as a second corner) of the first region A and the second region C. The first port <NUM> through which the refrigerant flows may be disposed adjacent to the first corner of the first region A. Also, the second port <NUM> through which the refrigerant is discharged may be disposed adjacent to the second corner of the second region C. According to this arrangement, the guide <NUM> may reduce the flow friction in the flow process until the refrigerant flowing into the first port <NUM> is discharged to the second port <NUM>, thereby reducing the pressure of the refrigerant. Therefore, since the flow of the refrigerant may be smoothly maintained even with a small amount of energy, energy required for cooling the battery module <NUM> may be saved.

The third flow path <NUM> disposed between the first flow path <NUM> and the second flow path <NUM> may have a plurality of flow paths such that the refrigerant may smoothly flow through the first flow path <NUM> and the second flow path <NUM>. Referring to <FIG>, the cooling frame <NUM> may have a plurality of avoidance portions <NUM> avoiding a portion in which the connection member <NUM> and the lower cover are coupled to each other, and a flow path may be formed between the avoidance portions <NUM>. For example, the third flow path <NUM> may include a side flow path 622a disposed between the avoidance portion <NUM> and the edge of the cooling frame <NUM> and a center flow path 622b disposed between the side flow path 622a and the plurality of avoidance portions <NUM>.

As such, since the cooling plate <NUM> has a plurality of flow paths between the avoidance portions <NUM>, interference with the coupling structure of the battery module <NUM> may be prevented and a smooth cooling flow path may be secured. Also, by forming a flow path by avoiding the portion in which the fastening member (e.g., <NUM> in <FIG>), the refrigerant may be prevented from leaking through the fastening portion.

However, the specific shape of the guide <NUM> is not limited to the above example. For example, differently from the example illustrated in <FIG>, the guide <NUM> formed in the first flow path <NUM> and the guide <NUM> formed on the second flow path <NUM> may include a plurality of guide protrusions arranged in different patterns.

Also, as illustrated in <FIG>, only one avoidance portion <NUM> may be formed. In this case, connection flow paths 622a may be formed along both ends of the avoidance portion <NUM> in the second direction (Y-axis direction), respectively. In the cooling plate in <FIG>, the configurations other than the shape of the avoidance portion <NUM> and the connection flow paths 622a may correspond to those of the cooling plate <NUM> in <FIG>.

Hereinafter, various shapes of the guide according to other embodiments will be described.

<FIG> are diagrams illustrating a cooling plate according to another example embodiment, viewed from above. In the cooling plate described with reference to <FIG>, the configurations other than the shape of the guide may correspond to those of the cooling plate described with reference to <FIG>, and accordingly, overlapping descriptions may not be provided.

Referring to <FIG>, guides 730a and 730b of a cooling plate <NUM> may include a plurality of guide protrusion groups <NUM> and <NUM> forming a pattern in a direction different from the fourth direction described with reference to <FIG>. For example, the guides 730a and 730b may include a plurality of guide protrusion groups <NUM> and <NUM> formed by a plurality of guide protrusions arranged in a fifth direction perpendicular to the fourth direction.

By this arrangement, the refrigerant flowing in through the first port <NUM> may diffuse widely into the first flow path <NUM> by the guide 730a having a pattern in the fifth direction. Accordingly, the entire first region may be rapidly cooled, which may be advantageous.

Referring to <FIG>, the guide <NUM> of the cooling plate <NUM> may have a pattern in which guide protrusions <NUM>, <NUM>, and <NUM> having different shapes and orientations may be alternately disposed.

For example, the guide <NUM> may include a first guide protrusion <NUM> extending in the fourth direction described above with reference to <FIG>, a second guide protrusion <NUM> extending in the fifth direction described with reference to <FIG>, and a third guide protrusion <NUM> having an approximately elliptical (or oval) shape.

The first guide protrusion <NUM>, the second guide protrusion <NUM>, and the third guide protrusion <NUM> may be alternately arranged in various manners. For example, as illustrated in <FIG>, the first guide protrusion <NUM> and the second guide protrusion <NUM> may be alternately arranged in the first direction (X-axis direction) and the second direction (Y-axis direction), and a third guide protrusion <NUM> may be disposed therebetween. In this case, the third guide protrusion <NUM> may be disposed between two first guide protrusions <NUM> and between two second guide protrusions <NUM>.

By the pattern structure of the guide as illustrated in <FIG>, the refrigerant may be induced to stably flow in the first direction (X-axis direction) and the second direction (Y-axis direction), and a decrease of pressure due to friction may be prevented.

Referring to <FIG> and <FIG>, the guides of the cooling plates 900a and 900b may be formed in a continuous wall shape to form flow paths <NUM> and <NUM> having a tubular shape. For example, the guide may be configured such that the refrigerant flowing in through the first port <NUM> may flow along the first flow path <NUM> and the second flow path <NUM> separated from each other and may be discharged through the second port <NUM>.

The first flow path <NUM> may form a first path through which the refrigerant may flow. Also, the second flow path <NUM> may be partitioned from the first flow path and may form a second flow path through which the refrigerant may flow. Accordingly, the refrigerant flowing in through the first port <NUM> may flow along two or more different paths, and may cool the battery module <NUM>, and may be discharged through the second port <NUM>.

Here, the first flow path <NUM> and the second flow path <NUM> may have paths bent multiple times, such that the refrigerant may flow evenly throughout regions corresponding to lower portions of the first sub-module and the second sub-module.

A portion of the first flow path <NUM> and a portion of the second flow path <NUM> may be spaced apart in the second direction (Y-axis direction) with the avoidance portion <NUM> of the cooling plates 900a and 900b interposed therebetween.

In this case, when a single avoidance portion <NUM> is provided as illustrated in <FIG>, a portion of the first flow path <NUM> and a portion of the second flow path <NUM> may be formed along the edge of the cooling frame with the avoidance portion <NUM> interposed therebetween.

Alternatively, as illustrated in <FIG>, when a plurality of avoidance portions <NUM> are provided in the first direction (Y-axis direction), which is the direction in which the connection member (e.g., <NUM> in <FIG>) extends, the first flow path <NUM> may include a first sub-flow path 921a and a second sub-flow path 921b spaced apart from each other with at least the avoidance portion <NUM> interposed therebetween. The first sub-flow path 921a and the second sub-flow path 921b may pass through the avoidance portion <NUM>, may merge into one path and may form the first flow path <NUM>. Similarly, the second flow path <NUM> may include a third sub-flow path 922a and a fourth sub-flow path 922b spaced apart from each other with at least one avoidance portion <NUM> interposed therebetween. The third sub-flow path 922a and the fourth sub-flow path 922b may pass through the avoidance portion <NUM>, may merge and may form the first flow path <NUM>.

A method of manufacturing a battery module may include a sub-module manufacturing step of manufacturing a plurality of sub-modules <NUM>, a connecting step of connecting the manufactured sub-modules <NUM> to each other via a connection member <NUM>, and a cover step of closing the upper and lower portions of the connected sub-modules by covering the portions with a case (e.g., an upper cover and a lower cover).

A sub-module may be a sub-unit included in at least a portion of a battery module, and a battery module may be manufactured by assembling a plurality of sub-modules. The plurality of sub-modules <NUM> manufactured as above may be assembled with each other via the connection member <NUM>. The plurality of sub-modules <NUM> connected to each other by the connection member <NUM> may be combined with the upper cover <NUM> and the lower cover <NUM> covering the upper and lower portions. The plurality of sub-modules 100a and 100b may be seated on the lower cover <NUM> which may integrally support the components. To increase heat dissipation efficiency, a heat dissipation member <NUM> may be applied to an upper surface of the lower cover <NUM>. Also, the connection member <NUM> disposed between the plurality of sub-modules 100a and 100b may be fastened to the lower cover <NUM> and the upper cover <NUM>. In this case, a bolting coupling method using a separate fastening member <NUM> may be applied.

The method of manufacturing the battery module <NUM> may further include a cooling plate coupling step of coupling the cooling plate <NUM> for cooling the sub-modules <NUM> to the lower cover <NUM>. In this case, the cooling plate <NUM> may be coupled to the lower cover <NUM> by welding, brazing, roll-bonding, thermal fusion, filler bonding, or friction welding. The step of assembling the cooling plate may already be performed before assembling the plurality of sub-modules <NUM> with the lower cover <NUM>. Alternatively, the coupling of the cooling plate <NUM> may be performed simultaneously in or after the process of coupling the plurality of sub-modules <NUM> to the lower cover <NUM>.

The manufacturing method of the battery module <NUM> is not limited to the above, and for example, the method may further include a step of connecting sensing modules (<NUM> in <FIG>) for sensing the state of the sub-modules <NUM> to each other, or a step of connecting a connector to the terminal unit (<NUM> in <FIG>) of the sub-modules <NUM>.

According to the aforementioned example embodiment, the cooling plate included in the battery module may form a cooling flow path for cooling the entirety of the plurality of sub-modules without interfering with a coupling structure of a connection member for connecting the plurality of sub-modules to each other.

Claim 1:
A battery module (<NUM>), comprising:
a first sub-module (100a) and a second sub-module (100b), each of the first and second sub-modules (100a, 100b) including a plurality of battery cells (<NUM>);
a lower cover (<NUM>) supporting the first sub-module (100a) and the second sub-module (100b);
a connection member (<NUM>) disposed between the first sub-module (100a) and the second sub-module (100b) and coupled to the lower cover (<NUM>); and
a cooling plate (<NUM>, <NUM>, <NUM>, 900a, 900b) configured to cool the first and second sub-modules (100a, 100b) and coupled to the lower cover (<NUM>) to form a flow path (<NUM>) through which a refrigerant can flow,
wherein at least a portion of the flow path (<NUM>) is disposed to oppose the connection member (<NUM>) with the lower cover (<NUM>) interposed therebetween,
wherein the cooling plate (<NUM>, <NUM>, <NUM>, 900a, 900b) includes an avoidance portion (<NUM>, <NUM>) provided to correspond to positions in which the connection member (<NUM>) and the lower cover (<NUM>) are coupled to each other.