Patent Description:
Currently commercialized secondary batteries include nickel cadmium batteries, nickel hydrogen batteries, nickel zinc batteries, lithium secondary batteries, and the like. Among these secondary batteries, because lithium secondary batteries have almost no memory effect compared to nickel-based secondary batteries, lithium secondary batteries are in the spotlight owing to the advantages of free charge and discharge, very low self discharge rate, and high energy density.

Such a lithium secondary battery mainly uses lithium-based oxides and carbon materials as positive electrode active material and negative electrode active materials, respectively. The lithium secondary battery includes an electrode assembly in which a positive electrode plate and a negative electrode plate coated with a positive electrode active material and a negative electrode active material respectively are arranged with a separator interposed therebetween, and a sheath material, that is, a battery pouch sheath material, that seals and accommodates the assembly together with an electrolyte solution.

Recently, secondary batteries are widely used not only in small devices such as portable electronic devices but also in medium and large devices such as vehicles and energy storage systems. When secondary batteries are used in such medium and large devices, a large number of secondary batteries are electrically connected in order to increase capacity and output power. In particular, pouch type secondary batteries are widely used in such medium and large devices because of advantages such as easy lamination.

Meanwhile, recently, as a need for a large-capacity structure has been increased, including utilization as an energy storage source, a demand for a battery module having a plurality of secondary batteries electrically connected in series and/or in parallel has increased.

In addition, it is common for such a battery pack to be further provided with an external housing formed of a metal material to protect a plurality of secondary batteries from external impact or accommodate and store the plurality of secondary batteries separated from a module case. However, when the external impact occurs, the shape of the external housing formed of the metal material is deformed, and a part of the eternal housing collides or contacts an internal configuration (the module case, a bus bar, a secondary battery, etc.) at a strong force, an internal damage and an internal short circuit are likely to occur. Accordingly, there was a problem in that secondary accidents such as explosion or fire of the secondary battery occurred.

Moreover, in the related art, in a process of inserting the module case into an inner space of the external housing, since damage to the internal components such as the module case and the bus bar is likely to occur, the process of inserting the module case into the external housing is difficult and takes a considerable time. As a result, the manufacturing cost of the battery module has increased.

Further prior art is disclosed in <CIT>.

The present disclosure is designed to solve the problems of the related art, and therefore the present disclosure is directed to providing a battery module that effectively protects internal components from external impact and increases manufacturing efficiency.

In one aspect of the present disclosure, there is provided a battery module including des a plurality of can type secondary batteries arranged to be laid down in a horizontal direction; a bus bar at least partially formed of an electrically conductive material to electrically connect the plurality of can type secondary batteries; and a module case in which an inner space is formed to accommodate the plurality of can type secondary batteries, the module case comprising an outer wall formed to surround the inner space and a bumper portion protruding from an outer surface of the outer wall in an outer direction to absorb an external impact.

The bumper portion forms a separation space from the outer wall of the module case.

The bumper portion includes an extension part protruding and extending from the outer wall of the module case in an outer direction; and a plate-shaped part bent and extending from an end portion of the extension part in an extending direction in a direction corresponding to the outer wall of the module case.

A rib protruding in the outer direction and linearly extending in at least two directions may be provided on an outer surface of the plate-shaped part.

The plate-shaped part may be provided with an inclined surface inclined more in an inner direction toward an outer periphery of the module case.

A part of the bus bar may be located in a separation space between the plate-shaped part of the bumper portion and the outer wall of the module case.

The module case may further include an auxiliary bumper portion protruding from an outer surface of the outer wall in the outer direction in a separation space between the plate-shaped part of the bumper portion and the outer wall of the module case.

The module case may further include a buffer pad having an elastic material in a separation space between the plate-shaped part of the bumper portion and the outer wall of the module case.

The battery module may further include an external housing having a box shape in which an inner space is formed to accommodate the module case, and having an inner surface provided with a projection portion protruding and extending in the inner direction in a position corresponding to the bumper portion.

A guide rail for guiding the module case to be inserted into the external housing may be provided in the inner surface of the external housing.

A guide groove indented in an inner direction and extending long in an up and down direction to be movable in the up and down direction along the guide rail may be formed in a part of the bumper portion.

In another aspect of the present disclosure, there is provided a battery pack including the at least one battery module.

In another aspect of the present disclosure, there is provided a vehicle including the at least one battery pack.

According to an aspect of the present disclosure, a module case is provided with a bumper portion configured to absorb external impact applied to a battery module, and thus when the external impact occurs in the battery module, the bumper portion absorbs the impact and reduces an amount of impact transferred to an embedded secondary battery. Accordingly, it is possible to increase the stability of the battery module.

In addition, according to an aspect of another embodiment of the present disclosure, the bumper portion is provided with an extension part and a plate-shaped part to secure a distance apart from an outer wall such that the bumper portion effectively absorbs the external impact applied to the battery module. Accordingly, the battery module of the present disclosure protects the embedded secondary battery from the external impact, thereby effectively preventing fire or explosion.

According to an aspect of the present disclosure, by forming ribs protruding in an outer direction and linearly extending on the outer surface of the plate-shaped part, the bumper portion may effectively reduce the weight or the material cost of the module case according to the addition of the bumper portion and maintaining proper rigidity. Moreover, the ribs may serve as relatively easily breaking and vulnerable parts to exert an excellent function in the impact absorption. For this reason, it is possible to increase the stability of the battery module. Furthermore, a separation space formed by the ribs may be utilized as a free space that may effectively absorb external impact transferred to the plate-shaped part.

Furthermore, according to an aspect of the present disclosure, by forming an inclined surface on the outer surface of the plate-shaped part, the bumper portion may induce an external object colliding with the bumper portion of the module case to miss in the left or right direction along the inclined surface formed in the bumper portion, thereby protecting a plurality of secondary batteries accommodated therein. Accordingly, it is possible to increase the stability of the battery module.

In addition, according to an aspect of the present disclosure, by placing a part of a bus bar in a separation space between the plate-shaped part of the bumper portion of the module case and the outer wall of the module case, the present disclosure may prevent the bus bar from contacting or colliding with an external conductive material and maintain electrical insulation from the outside. Accordingly, when the external impact occurs, a secondary accident due to electric leakage of the battery module may be prevented.

Moreover, according to an aspect of the present disclosure, the battery module of the present disclosure is provided with an auxiliary bumper portion in the separation space between the bumper portion and the outer wall of the module case, and thus the bumper portion and the auxiliary bumper portion may more effectively absorb the external impact applied to the battery module. Accordingly, the secondary battery embedded in the battery module may be protected from the external impact, thereby effectively preventing fire or explosion.

In addition, according to another aspect of the present disclosure, the module case is provided with a buffer pad in the separation space between the plate-shaped part of the bumper portion and the outer wall of the module case, thereby absorbing and buffering the external impact applied to the bumper portion, and thus the impact applied to the plurality of secondary batteries accommodated therein may be effectively reduced.

Further, according to another aspect of the present disclosure, by forming a projection portion protruding and extending in the inner direction in a position corresponding to the bumper portion on the inner surface of the external housing, a force transferred according to the external impact applied to the external housing may be induced to be intensively transferred from the projection portion to the bumper portion formed on the outer wall of the module case. Accordingly, the present disclosure has an effect capable of effectively reducing an amount of impact transferred to the secondary battery which is an internal component as compared with the case where an external impact is applied to other parts of the outer wall of the module case other than the bumper portion.

In addition, according to another aspect of the present disclosure, a guide rail is provided on the inner surface of the external housing, and a guide groove is formed on a part of the bumper portion, and thus the module case may be easily inserted into the external housing, thereby reducing the manufacturing process time. Moreover, the guide rail and the guide groove may effectively reduce the damage to the internal configuration that may occur when misassembled in a process of inserting the module case into the external housing. Accordingly, it is possible to effectively improve the manufacturing efficiency of the battery module.

<FIG> is a perspective view schematically showing a battery module according to an embodiment of the present disclosure. <FIG> is an exploded perspective view schematically showing some separated components of the battery module according to an embodiment of the present disclosure. In addition, <FIG> is a cross-sectional view schematically showing the configuration of a can type secondary battery according to an embodiment of the present disclosure.

Referring to <FIG>, the battery module <NUM> according to an embodiment of the present disclosure may include a plurality of can type secondary batteries <NUM>, at least one bus bar <NUM>, a module case <NUM>, and an internal plate <NUM>.

Here, the can type secondary battery <NUM> may include an electrode assembly <NUM>, a battery can <NUM>, and a cap assembly <NUM>.

The electrode assembly <NUM> may have a structure wound with a separator interposed between a positive electrode plate and a negative electrode plate, a positive electrode tab <NUM> is attached to the positive electrode plate and connected to the cap assembly <NUM>, and a negative electrode tab <NUM> is attached to the negative electrode plate and connected to the bottom end of the battery can <NUM>.

The battery can <NUM> may have an empty space formed therein to accommodate the electrode assembly <NUM>. In particular, the battery can <NUM> may has a cylindrical or square shape and may be configured with an open top end. In addition, the battery can <NUM> may be formed of a metal material such as steel or aluminum to secure rigidity and the like. In addition, the battery can <NUM> may has the bottom end to which the negative electrode tab is attached such that the lower portion of the battery can <NUM> and the battery can <NUM> may function as a negative electrode terminal.

The cap assembly <NUM> may be coupled to the top opening portion of the battery can <NUM> to seal the open end of the battery can <NUM>. The cap assembly <NUM> may have a shape such as a circular shape or a square shape according to the shape of the battery can <NUM>, and may include sub-components such as a top cap C1, a safety vent C2, and a gasket C3.

Here, the top cap C1 may be located on the uppermost portion of the cap assembly, may be configured to protrude in the upper direction. In particular, such a top cap C1 may function as a positive electrode terminal 111a in the can type secondary battery <NUM>. Accordingly, the top cap C1 may be electrically connected to another secondary battery <NUM>, a load, or a charging device through an external device, such as a bus bar <NUM>. The top cap C1 may be formed of, for example, a metal material such as stainless steel or aluminum.

The safety vent C2 may be configured to deform when the internal pressure of the secondary battery <NUM>, that is, the internal pressure of the battery can <NUM>, increases to a certain level or more. In addition, the gasket C3 may be formed of a material having electrical insulation such that the edge portions of the top cap C1 and the safety vent C2 may be insulated from the battery can <NUM>.

Meanwhile, the cap assembly <NUM> may further include a current interrupt member C4. The current interrupt member C4 is also called a current interrupt device (CID). When the internal pressure of the battery increases due to gas generation, and the shape of the safety vent C2 is reversed, a contact between the safety vent C2 and the current interrupt member C4 is broken or the current interrupt member C4 is damaged, and thus the electrical connection between the safety vent C2 and the electrode assembly <NUM> may be blocked.

The configuration of such a can type secondary battery <NUM> is well known to those skilled in the art at the time of filing of the present disclosure, and thus a more detailed description thereof will be omitted. In addition, although an example of the can type secondary battery <NUM> is illustrated in <FIG>, the battery module <NUM> according to the present disclosure is not limited to the configuration of a specific type of the can type secondary battery <NUM>. That is, various secondary batteries known at the time of filing of the present disclosure may be employed in the battery module <NUM> according to the present disclosure.

For example, the can type secondary battery <NUM> of <FIG> is illustrated with respect to the cylindrical secondary battery, but the square secondary battery may be applied to the battery module <NUM> according to the present disclosure.

Referring to <FIG> again, the plurality of can type secondary batteries <NUM> may be provided to be arranged in the front and back direction (Y direction) and the up and down direction (Z direction). For example, as illustrated in <FIG>, the plurality of can type secondary batteries <NUM> may be configured to be arranged in the front and back direction. In addition, the plurality of can type secondary batteries <NUM> may be configured to be arranged in the up and down direction. Moreover, the plurality of can type secondary batteries <NUM> may be arranged in which tubular shaped portions in a cylindrical battery can (<NUM> in <FIG>) face each other.

In particular, in the battery module <NUM> according to the present disclosure, the plurality of can type secondary batteries <NUM> may be configured to be laid down in a horizontal direction. Here, the horizontal direction means a direction parallel to the ground. That is, as illustrated in <FIG>, each can type secondary battery <NUM> may be configured to be elongated in a left and right direction (X-axis direction of the drawing). At this time, in some of the all can type secondary batteries <NUM>, when viewed in the F direction of <FIG>, the positive electrode terminal 111a and the negative electrode terminal 111b may be located in the left and right directions, respectively. In addition, in the remaining can type secondary batteries <NUM>, the positive electrode terminal 111a and the negative electrode terminal 111b of each can type secondary battery <NUM> may be located in the right and left directions, respectively.

Meanwhile, the terms indicating directions such as before, after, left, right, up and down described herein may vary depending on the position of an observer or the form in which an object is placed. However, in the present specification, for convenience of description, the directions of front, back, left, right, up, and down are identified and shown with respect to when viewed in the F direction.

Therefore, according to this configuration of the present disclosure, the height of the battery module <NUM> may be configured to be low. That is, when the can type secondary battery <NUM> is laid down, the battery module <NUM> having a shorter up and down height may be configured. Therefore, it is easy to design the battery module <NUM> having a low height.

Moreover, the bus bar <NUM> may electrically connect between the plurality of can type secondary batteries <NUM>, such as all of the secondary batteries <NUM>, or some of the secondary batteries <NUM>. To this end, at least a part of the bus bar <NUM> may be formed of an electrically conductive material. For example, the bus bar <NUM> may be formed of a metal material such as copper, aluminum, nickel, or the like.

In particular, in the present disclosure, the bus bar <NUM>, as shown in <FIG>, may be provided with a body portion <NUM> and the connection portion <NUM>.

The body portion <NUM> of the bus bar <NUM> may be configured in a plate shape. Moreover, the bus bar <NUM> may be configured in the form of a metal plate to ensure rigidity and electrical conductivity. In particular, the body portion <NUM> may be configured to be erected in the up and down direction (Z-axis direction of the drawing) along the electrode terminals <NUM> of the plurality of can type secondary batteries <NUM>. That is, in the present disclosure, when the plurality of can type secondary batteries <NUM> are lengthily laid down in the left and right direction (X-axis direction of the drawing) and arranged in the front and back direction (Y-axis direction of the drawing) and/or the up and down direction (Z-axis direction of the drawing), the electrode terminals <NUM> of the various secondary batteries <NUM> may be configured to be arranged in parallel in the front and back direction and the up and down direction. At this time, the body portion <NUM> may be configured to be erected flat in the front and back direction or the up and down direction as a plate shape according to the arrangement direction of the electrode terminals <NUM> of the plurality of secondary batteries <NUM>.

Moreover, the body portion <NUM> of the bus bar <NUM> may be configured to have an upper end portion bent in the inner direction. In addition, the upper end portion of the body portion <NUM> of the bus bar <NUM> may be a portion for sensing a voltage by a sensing member (not shown). Furthermore, a contact hole H3 for connection or contact of the sensing member may be formed in the bent portion of the bus bar <NUM>. For example, as illustrated in <FIG>, the upper end portion of the body portion <NUM> may be configured to be bent about <NUM> degrees toward the inner direction.

Specifically, the connection portion <NUM> may be configured to contact (join) the electrode terminals <NUM> of the plurality of can type secondary batteries <NUM> so as to electrically connect the plurality of can type secondary batteries <NUM>. In addition, a plurality of the connection portions <NUM> may be formed to extend from the body portion <NUM> in the front and back direction (Y direction). For example, the connection portions <NUM> may contact the electrode terminals <NUM> of some secondary batteries <NUM> among all the secondary batteries <NUM> to electrically connect the plurality of secondary batteries <NUM>.

Moreover, the bus bar <NUM> may contact and connect the same polarity of the plurality of can type secondary batteries <NUM> in parallel. Alternatively, the bus bar <NUM> may contact and electrically connect the electrode terminals <NUM> of some secondary batteries <NUM> among all the secondary batteries <NUM> in parallel and in series.

In addition, the battery module <NUM> may include a connection bus bar <NUM>. Specifically, the connection bus bar <NUM> may be configured to electrically connect the two or more bus bars <NUM>. For example, as shown in <FIG> and <FIG>, the battery module <NUM> may be provided with three connection bus bars <NUM>. The connection bus bar <NUM> may be configured such that one side is connected to a bus bar 221a of one module case <NUM> and the other side is connected to another bus bar 221b of another module case <NUM>.

Furthermore, the battery module <NUM> may include an external bus bar <NUM>. Specifically, the external bus bar <NUM> may serve as a final external input/output electrical terminal of the battery module <NUM>. To this end, the external bus bar <NUM> may be configured to contact a part of the bus bar (222a in <FIG>). For example, as illustrated in <FIG>, the battery module <NUM> may be provided with two external bus bars <NUM> that serve as an external input/output positive electrode terminal and an external input/output negative electrode terminal.

Meanwhile, the battery module <NUM> of the present disclosure may be configured such that the two or more module cases <NUM> and <NUM> are electrically connected to each other. Specifically, the battery module <NUM> may be configured such that the other module case <NUM> is stacked on the left or right side of the one module case <NUM>. For example, as illustrated in <FIG>, when viewed in the F direction, the battery module <NUM> may include a first module case <NUM> and a second module case <NUM> located on the right side of the first module case <NUM>.

Furthermore, an empty space may be formed in the module case <NUM> to accommodate the plurality of can type secondary batteries <NUM>. Specifically, the module case <NUM> may be provided with an outer wall 210c. The outer wall 210c may be formed to surround the empty space formed therein to accommodate the plurality of can type secondary batteries <NUM>. In addition, when viewed in the F direction of <FIG>, each of the module cases <NUM> and <NUM> may be provided with a first outer wall 210c1, a second outer wall 210c2, a third outer wall 210c3, a fourth outer wall 210c4, a fifth outer wall 210c5, and a sixth outer wall 210c6 that are formed in the front, back, up, down, left, and right directions to form the inner space. For example, as shown in <FIG>, each of the first module case <NUM> and the second module case <NUM> may be provided with the first outer wall 210c1, the second outer wall 210c2, the third outer wall 210c3, the fourth outer wall 210c4, the fifth outer wall 210c5, and the sixth outer wall 210c6.

Accordingly, according to this configuration of the present disclosure, the module case <NUM> is provided with the outer wall 210c, thereby effectively protecting the plurality of secondary batteries <NUM> accommodated therein from external impact.

In addition, the at least two can type secondary batteries <NUM> may be accommodated to be laid down in the horizontal direction (X-axis direction) in the inner space of the module case <NUM>. The stack direction is not necessarily limited to one direction, and may be the up and down direction (Z-axis direction) according to a direction in which the can type secondary battery <NUM> is laid down. For example, as illustrated in <FIG>, the at least two or more can type secondary batteries <NUM> may be accommodated to be laid down in the left and right direction (X-axis direction) in the inner space of each of the first module case <NUM> and the second module case <NUM>.

In addition, the first module case <NUM> may be provided with a first frame 212a and a second frame 212b. Here, the first frame 212a and the second frame 212b may be configured to meet and join each other in one side and the other side in the left and right direction (X direction). For example, in the configuration of <FIG>, when viewed in the F direction of <FIG>, the first frame 212a may be disposed on the left side of the plurality of secondary batteries <NUM> to accommodate the left portions of the plurality of secondary batteries <NUM>. In addition, the second frame 212b may be positioned on the right side of the plurality of secondary batteries <NUM> to accommodate the right portions of the plurality of secondary batteries <NUM>.

In particular, the first frame 212a and the second frame 212b may be configured to cover one side and the other side of the plurality of secondary batteries <NUM>, respectively, to wholly cover the outer surface of the can type secondary batteries <NUM> excluding the electrode terminal <NUM>. For example, when the can type secondary battery <NUM> is the cylindrical secondary battery <NUM>, the first frame 212a and the second frame 212b wholly cover the outer surface of the cylindrical battery, such that the side surface of the secondary battery <NUM> in the up and down direction may be configured not to be exposed to the outside of the battery module <NUM>.

For example, in the configuration of <FIG>, the first frame 212a may be disposed on the left side of the plurality of secondary batteries <NUM> to accommodate the left portions of the plurality of secondary batteries <NUM>. In addition, the second frame 212b may be positioned on the right side of the plurality of secondary batteries <NUM> to accommodate the right portions of the plurality of secondary batteries <NUM>.

Likewise, the second module case <NUM> may be provided with a first frame 214a and the second frame 214b of the same structure as that of the first frame 212a and the second frame 212b of the first module case <NUM>.

Therefore, according to this configuration of the present disclosure, since the side exposure of the secondary battery <NUM> is blocked by the module case <NUM>, the insulating property of the secondary battery <NUM> may be improved, and the secondary battery <NUM> may be protected from external physical and chemical factors.

In addition, the second frame 212b may be configured to be connected to one side of the first frame 212a in the horizontal direction, as shown in <FIG>. In addition, the first frame 212a and the second frame 212b may be fixed in a male and female coupling structure. For example, as shown in <FIG>, a coupling groove 212a1 is formed in the first frame 212a, and a coupling protrusion 212b1 is formed on the second frame 212b and thus the coupling groove 212a1 and the coupling protrusion 212b1 may be coupled to each other.

Furthermore, the second module case <NUM> may be provided with the first frame 214a and the second frame 214b. Here, when the first frame 214a and the second frame 214b are compared with the first frame 212a and the second frame 212b of the first module case <NUM> described above, the first frame 214a and the second frame 214b may have the same configuration, except that the left and right positions of the first frame 214a and the second frame 214b are reversely arranged. Specifically, when the front and rear positions of the second module case <NUM> rotate by <NUM> degrees, the first frame 214a and the second frame 214b of the second module case <NUM> may have the same arrangement as the first frame 212a and the second frame 212b of the first module case <NUM>.

Accordingly, the first frame 214a and the second frame 214b of the second module case <NUM> have the same shapes as the first frame 212a and the second frame 212b of the first module case <NUM>, and thus detailed descriptions of the first frame 214a and the second frame 214b of the second module case <NUM> will be omitted.

<FIG> is a perspective view schematically showing a module case of a battery module according to an embodiment of the present disclosure. <FIG> is a right perspective view schematically showing a module case of a battery module according to an embodiment of the present disclosure.

Referring to <FIG> and <FIG>, the module case <NUM> may be provided with a bumper portion <NUM> to absorb external impact applied to the battery module <NUM>. Specifically, the bumper portion <NUM> may be formed on an outer wall 210c1 of the module case <NUM>. For example, as illustrated in <FIG> and <FIG>, the bumper portion <NUM> may be formed on each of the front outer wall 210c1 and the rear outer wall 210c2 of the module case <NUM>.

In addition, the bumper portion <NUM> may be configured to protrude in an outer direction from the outer surface of the outer wall 210c. For example, as illustrated in <FIG>, eight bumper portions <NUM> formed to protrude forward from the front outer wall 210c1 of the module case <NUM> may be formed. In addition, although not shown in the drawing, eight bumper portions <NUM> formed to protrude rearward from the rear outer wall 210c2 of the module case <NUM> may be formed.

In addition, the bumper portion <NUM> may be configured to form a separation space from the outer wall 210c of the module case <NUM>. That is, the bumper portion <NUM> may have a space S apart from the outer wall 210c by a predetermined distance. For example, as illustrated in <FIG>, each of the eight bumper portions <NUM> may have the space S apart from the front outer wall 210c1 of the module case <NUM>. In addition, although not shown in the drawing, a plurality of bumper portions <NUM> formed to protrude rearward from the rear outer wall 210c2 of the module case <NUM> may be formed. Moreover, each of the bumper portions <NUM> provided on the rear outer wall 210c2 may have the space S apart from the rear outer wall 210c2 of the module case <NUM>.

In this regard, the bumper portion <NUM> secures a distance apart from the outer wall 210c of the module case <NUM>, and thus external impact applied to the battery module <NUM> is not directly transferred to the embedded secondary battery <NUM>, and the bumper portion <NUM> may preferentially collide with the outer wall 210c to cause the bumper portion <NUM> to absorb more external impact.

Accordingly, according to this configuration of the present disclosure, the module case <NUM> is provided with the bumper portion <NUM> configured to absorb the external impact applied to the battery module <NUM>, and thus when the external impact occurs in the battery module <NUM>, the bumper portion <NUM> may preferentially absorb the impact to protect the embedded secondary battery <NUM>. Accordingly, the stability of the battery module <NUM> may be increased.

In addition, the bumper portion <NUM> may have an extension part <NUM> and a plate-shaped part <NUM>. Here, the extension part <NUM> may have a shape protruding and extending in the outer direction from the outer wall 210c of the module case <NUM>. Specifically, the extension part <NUM> may be configured to separate the plate-shaped part <NUM> apart from the outer wall 210c of the module case <NUM> by a predetermined distance. The bumper portion <NUM> secures a distance apart from the outer wall 210c of the module case <NUM>, and thus the external impact applied to the battery module <NUM> is not directly transferred to the embedded secondary battery <NUM>, and the bumper portion <NUM> may preferentially collide to cause the bumper portion <NUM> to absorb more external impact.

In addition, the plate-shaped part <NUM> may have a shape curved and extending from an end portion of the extension part <NUM> in the extension direction to a direction corresponding to the outer wall 210c of the module case <NUM>.

Therefore, according to this configuration of the present disclosure, the bumper portion <NUM> is provided with the extension part <NUM> and the plate-shaped part <NUM> to secure the distance apart from the outer wall, and thus the bumper portion <NUM> may effectively absorb the external impact applied to the battery module <NUM>. Accordingly, the secondary battery <NUM> embedded in the battery module <NUM> is protected from the external impact, thereby effectively preventing fire or explosion.

Further, a linear rib R2 may be formed on the outer surface of the plate shape in the plate-shaped part <NUM>. Specifically, the rib R2 may protrude in the outer direction and linearly extend in at least two directions. For example, as shown in <FIG> and <FIG>, when viewed from the F direction of <FIG>, the linear ribs R2 may have a lattice shape in which the linear ribs R2 extending in the left and right direction (X direction) and the up and down direction (Z direction) intersect each other.

Furthermore, the plate-shaped part <NUM> may have a separation space formed by the rib R2 on the outer surface. That is, the plate-shaped part <NUM> may have the separation space corresponding to a size protruding in the outer direction between the rib R2 and the other rib R2. Alternatively, when the ribs R2 extend in the lattice shape, the plate-shaped part <NUM> may have the separation space as much as a size protruding in the outer direction every between the ribs R2 of a lattice pattern.

Therefore, according to this configuration of the present disclosure, by forming the ribs R2 protruding in the outer direction and linearly extending on the outer surface of the plate-shaped part <NUM>, the bumper portion <NUM> may effectively reduce the weight or the material cost of the module case <NUM> according to the addition of the bumper portion <NUM> and maintaining proper rigidity. Moreover, the ribs R2 may serve as relatively easily breaking and vulnerable parts to exert an excellent function in the impact absorption. For this reason, it is possible to increase the stability of the battery module <NUM>. Furthermore, a separation space formed by the ribs R2 may be utilized as a free space that may effectively absorb the external impact transferred to the plate-shaped part <NUM>.

In addition, the plate-shaped part <NUM> may have a curved surface such that the center of the body protrudes convexly on the outer surface in the outer direction. Furthermore, the plate-shaped part <NUM> may have a plate shape in which the center of the body is convexly curved in the outer direction. For example, as illustrated in <FIG>, in the plate-shaped part <NUM> of a partial bumper portion 240a, the plate-shaped part <NUM> may also have a curved surface in which the center of the body convexly protrudes forward. The plate-shaped part <NUM> may also have a plate shape in which the center of the body is convexly curved forward.

In addition, an inclined surface K1 inclined in the inner direction may be formed in the plate-shaped part <NUM>. Specifically, the inclined surface K1 may be more inclined in the inner direction in the plate-shaped part <NUM> toward the outer periphery of the outer wall 210c of the module case <NUM>. That is, the inclined surface K1 may have a shape in which the thickness of the plate-shaped part <NUM> becomes smaller toward the outer periphery of the plate-shaped part <NUM>. For example, referring to <FIG> and <FIG>, in the eight bumper portions <NUM>, the inclined surface K1 which is adjacent to the outer periphery of the outer wall 210c1 of the module case <NUM> and which is inclined backward in the left end portion of the outer surface of the plate-shaped part <NUM>, the right end portion, or the left end portion and the right end portion may be formed.

Therefore, according to this configuration of the present disclosure, by forming the inclined surface K1 on the outer surface of the plate-shaped part <NUM>, the bumper portion <NUM> may induce an external object colliding with the bumper portion <NUM> of the module case <NUM> to miss (obliquely pass by) in the left or right direction along the inclined surface K1 formed on the bumper portion <NUM>, thereby protecting the plurality of secondary batteries <NUM> accommodated therein. Accordingly, the stability of the battery module <NUM> may be increased.

<FIG> is a right perspective view schematically showing some bus bars of a battery module according to an embodiment of the present disclosure.

Referring back to <FIG> together with <FIG> and <FIG>, the bus bar 221a mounted on the one module case <NUM> may be provided with an expansion portion <NUM> so as to be connected to the bus bar 221b mounted on the other module case <NUM>. The expansion portion <NUM> may have a shape extending from the body portion <NUM> of the bus bar <NUM> in a perpendicular direction. A coupling hole H4 for bolt fastening the connection bus bar <NUM> may be formed in the expansion portion <NUM>. The expansion portion <NUM> may be coupled to the connection bus bar <NUM> to electrically connect the plurality of secondary batteries <NUM> mounted on each of the two module cases <NUM> and <NUM>.

For example, as shown in <FIG>, each of the two bus bars 221a and 221b provided in the two module cases <NUM> and <NUM> may further include the expansion portion <NUM> unlike the other bus bar <NUM>. The expansion portion <NUM> may have a shape curved in the left or right direction from the body portion <NUM> of the bus bar <NUM>. In addition, three coupling holes H4 for bolt fastening may be formed in the expansion portion <NUM>.

A part of the bus bar <NUM> may be positioned in the space S apart between the plate-shaped part <NUM> of the bumper portion <NUM> and the outer wall 210c of the module case <NUM>. Here, the part of the bus bar <NUM> may be the expansion portion <NUM>. For example, the expansion portion <NUM> of the bus bar <NUM> may be positioned in the space S apart between the plate-shaped part <NUM> of the bumper portion <NUM> and the outer wall 210c of the module case <NUM>. For example, as shown in <FIG> and <FIG>, the expansion portions <NUM> of the two bus bars 221a and 221b may be positioned between the plate-shaped part <NUM> of the bumper portion <NUM> and the front outer wall 210c1 of the module case <NUM>.

Therefore, according to this configuration of the present disclosure, a part of the bus bar <NUM> is configured to be positioned in the space S apart between the plate-shaped part <NUM> of the bus bar <NUM> and the outer wall 210c of the module case <NUM>, and thus the bumper portion <NUM> of the module case <NUM> may prevent contact or collision with an external conductive material and maintain an electrical insulation from the outside. Accordingly, when an external impact occurs, a secondary accident due to the electric leakage of the battery module <NUM> may be prevented.

Furthermore, referring to <FIG> and <FIG> again, an auxiliary bumper portion <NUM> may be further formed in the module case <NUM>. Specifically, the auxiliary bumper portion <NUM> may be positioned in the space S apart between the bumper portion <NUM> and the outer wall 210c of the module case <NUM>. In addition, the auxiliary bumper portion <NUM> may have a plate-shaped part 244a on which a linear rib R3 is formed. The rib R3 of the plate-shaped part 244a may have a shape protruding and extending in the inner direction. However, the auxiliary bumper portion <NUM> is not provided with the extension part <NUM> unlike the bumper portion <NUM>. For example, as illustrated in <FIG> and <FIG>, eight auxiliary bumper portions <NUM> positioned inside the four bumper portions <NUM> may be formed on the front outer wall 210c of the module case <NUM>.

Moreover, the auxiliary bumper portion <NUM> may be configured to form a separation space by a predetermined distance between the plate-shaped part <NUM> of the bumper portion <NUM> and the auxiliary bumper portion <NUM>. The separation space between the bumper portion <NUM> and the auxiliary bumper portion <NUM> may be utilized as a free space that may effectively absorb external impact transferred to the bumper portion <NUM> and the auxiliary bumper portion <NUM>.

Accordingly, according to this configuration of the present disclosure, by providing the auxiliary bumper portion <NUM> in the space S apart between the bumper portion <NUM> and the outer wall 210c of the module case <NUM>, the bumper portion <NUM> and the auxiliary bumper portion <NUM> may more effectively absorb external impact applied to the battery module <NUM>. Accordingly, the secondary battery <NUM> embedded in the battery module <NUM> is protected from the external impact, thereby effectively preventing fire or explosion.

In addition, referring to <FIG> again, at least one support ribs R1 may be formed on the extension part <NUM> of the bumper portion <NUM> of the module case <NUM>. Specifically, the support rib R1 may have structure in which a part is connected to each of the extension part <NUM> and the outer wall 210c of the module case <NUM>. For example, as illustrated in <FIG>, a plurality of support ribs R1 may be formed in the extension parts <NUM> of the two bumper portions <NUM>. At this time, the shape of the support rib R1 may be a triangular plate shape.

Accordingly, according to this configuration of the present disclosure, by forming the at least one support ribs R1 on the extension part <NUM>, the bumper portion <NUM> may fix the extension part <NUM> not to be easily bent or broken even if an external impact occurs in the bumper portion <NUM>, and thus the defense power of the bumper portion <NUM> against the external impact may be further increased.

<FIG> is a right perspective view schematically showing a module case of a battery module according to another embodiment of the present disclosure.

Referring to <FIG>, the module case <NUM> may further include a buffer pad <NUM>. The buffer pad <NUM> may have an elastic material. Here, the elastic material may be, for example, synthetic rubber, latex, or silicone-based polymer. The buffer pad <NUM> may be provided in the separation space between the plate-shaped part <NUM> of the bumper portion <NUM> and the outer wall of the module case <NUM>. At this time, the buffer pad <NUM> may be formed after filling the separation space between the plate-shaped part <NUM> of the bumper portion <NUM> and the outer wall of the module case <NUM> in a liquid form and then cured.

For example, as shown in <FIG>, four buffer pads <NUM> may be respectively provided in spaces apart inside four bumper portions <NUM>. The buffer pad <NUM> may have, for example, at least part of the silicone-based polymer.

Therefore, according to this configuration of the present disclosure, by providing the buffer pad <NUM> in the separation space between the plate-shaped part <NUM> of the bumper portion <NUM> and the outer wall of the module case <NUM>, the module case <NUM> may absorb and buffer external impact applied to the bumper portion <NUM>, thereby effectively reducing the impact applied to the plurality of secondary batteries <NUM> accommodated therein.

<FIG> is a perspective view schematically showing a battery module according to another embodiment of the present disclosure. <FIG> is an exploded perspective view schematically showing separated internal components of the battery module of <FIG>. <FIG> is a plan view schematically showing some components of the battery module of <FIG>.

Referring to <FIG>, the battery pack 200B according to another embodiment of the present disclosure may further include an external housing <NUM>.

Here, the external housing <NUM> may have a box shape in which an inner space is formed to accommodate the module case <NUM>. Specifically, the external housing <NUM> may be provided with an outer wall 250a forming a macroscopic hexahedron configured to form the inner space.

In addition, the external housing <NUM> may include an upper cap <NUM>, an intermediate case <NUM>, and a lower support portion <NUM>. Specifically, when viewed in the F direction, the intermediate case <NUM> is coupled to the lower portion of the upper cap <NUM>, and the lower support portion <NUM> may be coupled to the lower portion of the intermediate case <NUM>. More specifically, the upper cap <NUM> may be provided with an upper wall and a side wall to cover an upper portion of the module case <NUM> accommodated inside the external housing <NUM>. In addition, the intermediate case <NUM> may have a square tubular shape opened in the up and down direction. Further, the lower support portion <NUM> may be a box shape with an open upper portion and provided with a side wall and a lower wall.

In addition, a projection portion P1 may be provided on the inner surface of the external housing <NUM>. Specifically, the projection portion P1 may be formed to protrude and extend in the inner direction from a position corresponding to the bumper portion <NUM>. Moreover, the projection portion P1 may have a shape extending in the up and down direction. For example, as illustrated in <FIG>, a plurality of projection portions P1 protruding in the inner direction and having the thickness in the horizontal direction gradually decreasing in the protruding direction may be formed on the inner surface of the external housing <NUM>. In addition, some of all the projection portions P1 may be formed in a position corresponding to the bumper portion <NUM> formed on the outer wall of the module case <NUM>. Furthermore, the projection portion P1 may extend to upper and lower ends of the inner surface of the intermediate case <NUM>.

Accordingly, according to this configuration of the present disclosure, by forming the projection portion P1 protruding and extending in the inner direction in the position corresponding to the bumper portion <NUM> on the inner surface of the external housing <NUM>, a force transferred according to the external impact applied to the external housing <NUM> may be induced to be intensively transferred from the projection portion P1 to the bumper portion <NUM> formed on the outer wall 210c of the module case <NUM>. Accordingly, the present disclosure has an effect capable of effectively reducing an amount of impact transferred to the secondary battery <NUM> which is an internal component as compared with the case where the external impact is applied to other parts of the outer wall 210c of the module case <NUM> other than the bumper portion <NUM>.

Referring to <FIG> again, a guide rail G1 configured to guide the insertion of the module case <NUM> may be provided on the inner surface of the external housing <NUM>. Specifically, the guide rail G1 may be formed on the inner surface of the intermediate case <NUM>. The guide rail G1 may partially have a circular column shape protruding from the inner surface of the intermediate case <NUM> in the inner direction and lengthily extending in the up and down direction. That is, the guide rail G1 may extend and protrude from the inner surface of the external housing <NUM> in the inner direction.

Further, the end portion of the guide rail G1 in the protruding direction may have a curved surface (a convex curved surface in the inner direction) having a circular arc shape on the plane. For example, as illustrated in <FIG>, four guide rails G1 may be formed on the inner surface of the external housing <NUM>. In addition, the four guide rails G1 may be formed in a position corresponding to the outer wall on which the bumper portion <NUM> of the module case <NUM> is formed.

Again, referring to <FIG> and <FIG> together with <FIG> and <FIG>, in a part of the bumper portion <NUM>, a guide groove <NUM> configured to be movable in the up and down direction along the guide rail G1 may be formed. Specifically, the guide groove <NUM> may have a shape indented in the inner direction of the module case <NUM>. More specifically, the guide groove <NUM> may be indented in a shape corresponding to an outer shape of the guide rail G1 in the protruding direction.

In addition, the guide groove <NUM> may have the indented shape lengthily extending in the up and down direction. Furthermore, the guide groove <NUM> may be a part extending from the extension part <NUM> in the left and right direction. Alternatively, the guide groove <NUM> may be formed in the left and right sides of the extension part <NUM>. Further, the guide groove <NUM> may be formed in a position corresponding to the guide rail G1.

For example, as illustrated in <FIG>, the guide groove <NUM> may be formed in a part of the two bumper portions 240a respectively formed on the front outer wall 210c1 and the rear outer wall 210c2 of the module case <NUM>. The guide groove <NUM> may be in a shape concavely indented in the inner direction and lengthily extending in the up and down direction.

Accordingly, according to this configuration of the present disclosure, the guide rail G1 is provided on the inner surface of the external housing <NUM>, and the guide groove <NUM> is formed on a part of the bumper portion <NUM>, and thus the module case <NUM> may be easily inserted into the external housing <NUM>, thereby reducing the manufacturing process time. Moreover, the guide rail G1 and the guide groove <NUM> may effectively reduce the damage to the internal configuration that may occur when misassembled in a process of inserting the module case <NUM> into the external housing <NUM>. Accordingly, it is possible to effectively improve the manufacturing efficiency of the battery module <NUM>.

Meanwhile, a battery pack (not shown) according to an embodiment of the present disclosure may include at least one battery module <NUM>. Further, 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, a fuse, etc..

Meanwhile, an electronic device (not shown) according to an embodiment of the present disclosure includes the at least one battery module <NUM> described above. The electronic device may further include a device housing (not shown) provided with an accommodation space for accommodating the battery module <NUM> and a display unit that allows a user to check a state of charging of the battery module <NUM>.

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

Meanwhile, in the present specification, although the terms indicating directions such as up, down, left, right, front, and back are used, it is apparent to those skilled in the art that these terms are for convenience of explanation only and vary depending on the position of a target object or the position of an observer.

Claim 1:
A battery module (<NUM>) comprising:
a plurality of can type secondary batteries (<NUM>) arranged to be laid down in a horizontal direction;
a bus bar (<NUM>) at least partially formed of an electrically conductive material to electrically connect the plurality of can type secondary batteries (<NUM>); and
a module case (<NUM>) in which an inner space is formed to accommodate the plurality of can type secondary batteries (<NUM>), the module case (<NUM>) comprising an outer wall (210c) formed to surround the inner space and a bumper portion (<NUM>) protruding from an outer surface of the outer wall (210c) in an outer direction to absorb an external impact,
wherein the bumper portion (<NUM>) forms a separation space from the outer wall (210c) of the module case (<NUM>),
characterized in that the bumper portion (<NUM>) comprises:
an extension part (<NUM>) protruding and extending from the outer wall (210c) of the module case (<NUM>) in an outer direction; and
a plate-shaped part (<NUM>) bent and extending from an end portion of the extension part (<NUM>) in an extending direction in a direction corresponding to the outer wall (210c) of the module case (<NUM>).