Patent ID: 12206126

DETAILED DESCRIPTION

Hereinafter, the preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Prior to the description, it should be understood that the terms or words used in the specification and the appended claims should not be construed as being limited to general and dictionary meanings, but rather interpreted based on the meanings and concepts corresponding to the technical aspects of the present disclosure on the basis of the principle that the inventor is allowed to define the terms appropriately for the best explanation. Therefore, the embodiments described herein and illustrations shown in the drawings are just a most preferred embodiment of the present disclosure, but not intended to fully describe the technical aspects of the present disclosure, so it should be understood that a variety of other equivalents and modifications could have been made thereto at the time that the application was filed.

First, a schematic structure of a battery module according to an embodiment of the present disclosure will be described with reference toFIGS.1and2.FIG.1is a perspective view of the battery module1according to an embodiment of the present disclosure.FIG.2is a diagram showing the battery module1ofFIG.1from which a second housing cover230is removed.

Referring toFIGS.1and2, the battery module1according to an embodiment of the present disclosure includes a module housing200. The module housing200includes a sub module (not shown) and a variable partition structure400using hinges. Additionally, the battery module1may further include a gasket300to ensure sealability.

The module housing200includes a lower housing210, a first housing cover220and a second housing cover230. The lower housing210, the first housing cover220and the second housing cover230are coupled with a bolt B. The module housing200may receive a cell or the sub module therein. The first housing cover220and the second housing cover230are placed on top in the Z axis direction of the lower housing210, and coupled to form a flame arresting structure. In this instance, the first housing cover220forms an exhaust path lower plate, and the second housing cover230forms an exhaust path upper plate.

The variable partition structure400using hinges is fixed and received on the first housing cover220and forms a flame exhaust path P between the first housing cover220and the second housing cover230.

By the battery module1, it is possible to capture flames between the first housing cover220and the second housing cover230when a fire occurs in the sub module. The battery module1may force gas out of the battery module1through an outlet H2of the second housing cover230, and arrest flames in the battery module1or bring flames to end.

It is possible to freely adjust the length and direction of the variable partition structure400using hinges. Accordingly, it is possible to conform to different battery module sizes. The variable partition structure400using hinges can freely adjust the movement paths of gas and flames occurring in the battery module1. It is possible to easily adjust the length of the exhaust paths of gas and flames by a task of changing the variable partition structure400using hinges without needing to replace the module housing200even though there are changes in the applied voltage and capacity of the battery cell.

Hereinafter, the detailed structure and manufacturing method of the battery module1will be described in detail with reference toFIGS.3to11together withFIGS.1and2.

FIG.3is a diagram showing the lower housing210included in the battery module1shown inFIG.1.

Referring toFIG.3, the lower housing210corresponds to a top open bottom plate. The lower housing210has an opening O on top in the Z axis direction, and may receive the sub module in a receiving space formed at the center. The lower housing210includes a sub module receiving part211recessed down (Z axis direction) at the center and a housing extended part212extending outward from the top periphery of the sub module receiving part211on the periphery of the opening O. The sub module is received in the sub module receiving part211. The housing extended part212has a plurality of first coupling holes212athereon at a predetermined interval. The first coupling hole212aprovides a space into which the bolt B is inserted to couple the lower housing210to the first housing cover220and the second housing cover230.

FIG.4is a diagram showing the sub module100included in the battery module1.

Referring toFIG.4, the sub module100includes a plurality of battery cells110received in the internal receiving space of the lower housing210and stacked in contact with each other. Additionally, in addition of a cell stack formed by stacking the plurality of battery cells110, the sub module100may further include a pair of busbar frames120each coupled to two sides in the lengthwise direction (X axis direction) of the cell stack.

The battery cell110may include, for example, a pouch type battery cell. The battery cell110has a pair of electrode leads111. The pair of electrode leads111may be drawn on the two sides in the lengthwise direction (X axis direction) of the battery cell110.

The busbar frames120are coupled to the cell stack and electrically connect the plurality of battery cells110. That is, the electrode leads111are drawn through slits formed in the busbar frames120and coupled to busbars provided in the busbar frames120. An electrical connection between adjacent battery cells110is established through the coupling between the electrode leads111and the busbars.

FIG.5is a diagram showing a process of receiving the sub module100in the lower housing210ofFIG.3.

Referring toFIG.5, to assemble the battery module1, first, the lower housing210is prepared, and the sub module100is inserted down (in the Z axis direction) through the opening O of the lower housing210. The sub module100is seated in the sub module receiving part211.

FIG.6is a diagram showing the first housing cover220included in the battery module1.

Referring toFIG.6, the first housing cover220is in the shape of a plate of an approximately rectangular shape on the X-Y plane, and has a gas inlet H1formed therethrough at one of the four corner areas. The first housing cover220includes a cover receiving part221recessed down (Z axis direction) and a cover extended part222extending outward from the top periphery of the cover receiving part221. The location of the gas inlet may vary depending on the intake and exhaust direction. In this embodiment, the gas inlet H1is provided at the corner area of the cover receiving part221. To ensure a sufficient length of the flame exhaust path, the gas inlet H1is preferably formed at the corner area of the cover receiving part221, but the gas inlet may be formed at the central area of the cover receiving part221according to the design.

A plurality of insertion grooves221afor inserting/fixing the variable partition structure400using hinges is provided on the periphery of the inner side wall of the cover receiving part221. The cover receiving part221has grooves221b,221cinto which the partition structure400using hinges is inserted. The plurality of insertion grooves221aand the plurality of grooves221b,221care provided, and some of them may be used to insert/fix the variable partition structure400using hinges. The designer may implement the variable partition structure400using hinges to form various flame exhaust paths by selecting some of the plurality of insertion grooves221aand the plurality of grooves221b,221c.

A plurality of second coupling holes222aformed at a predetermined interval is provided on the cover extended part222. The second coupling hole222aprovides a space in which the bolt B is inserted to couple the first housing cover220to the lower housing210and the second housing cover230.

The first housing cover220may have a sealing member groove222bformed in the cover extended part222, and in this case, a sealing member may be inserted into the sealing member groove222b.

FIG.7is a diagram showing a process of coupling the lower housing210to the first housing cover220.

Referring toFIG.7, the first housing cover220covers the opening O of the lower housing210in which the sub module100is received and is coupled to the top of the lower housing210. Specifically, the coupling between the first housing cover220and the lower housing210is performed in a state of contact between the cover extended part222of the first housing cover220and the housing extended part212of the lower housing210. When the first housing cover220is coupled to the lower housing210, the first coupling hole212aand the second coupling hole222aare arranged at one-to-one matching locations so that they are vertically aligned, and the gas inlet H1communicates with the sub module receiving part211of the lower housing210. Accordingly, when gas and flames occur due to the venting of a certain battery cell110of the sub module100in the lower housing210, the gas and flames enter the cover receiving part221of the first housing cover220through the gas inlet H1.

FIG.8is a diagram showing a process of installing the variable partition structure400using hinges in the first housing cover220.

Referring toFIG.8, the variable partition structure400using hinges is fixed and received on the first housing cover220. In this instance, the insertion grooves221aand the grooves221b,221cdescribed with reference toFIG.6are used. The insertion grooves221aand the grooves221b,221callow the variable partition structure400using hinges to be received in the cover receiving part221of the first housing cover220well without movement or separation. The direction of the variable partition structure400using hinges and/or the number of unit structures of the variable partition structure400using hinges may vary depending on the exhaust path. Its detailed description will be provided below.

FIG.9is a diagram showing a process of installing the sealing member in the first housing cover220.

As described with reference toFIG.6, the first housing cover220may have the sealing member groove222bformed in the cover extended part222, and in this case, the sealing member such as the gasket300may be inserted into the sealing member groove222b. When the gasket300as the sealing member is inserted as shown inFIG.9, it is possible to enhance the sealability of the coupling interface between the first housing cover220and the second housing cover230.

FIG.10is a diagram showing a process of installing the second housing cover230on the first housing cover220, andFIG.11is a diagram showing a process of coupling the lower housing210, the first housing cover220and the second housing cover230.

Referring toFIG.10, the second housing cover230is in the shape of a plate of an approximately rectangular shape on the X-Y plane and includes the gas outlet H2, and the second housing cover230is coupled to the first housing cover220from the top of the first housing cover220. In the same way as the gas inlet, the location of the gas outlet may vary depending on the intake and exhaust direction, and in this embodiment, the gas outlet formed at one of the corner areas of the second housing cover230is taken as an example. To ensure a sufficient length of the flame exhaust path, the distance between the gas outlet H2and the gas inlet H1is preferably as long on the X-Y plane as possible. Since the gas inlet H1formed at any one corner area of the cover receiving part221is taken as an example, the gas outlet H2may be formed at other corner area of the second housing cover230. The gas outlet H2may be formed at the central area of the second housing cover230according to the design.

A plurality of third coupling holes232aformed at a predetermined interval is provided in the second housing cover230. The third coupling hole232aprovides a space in which the bolt B is inserted to couple the first housing cover220to the lower housing210and the second housing cover230.

In this instance, the first coupling hole212aof the housing extended part212, the second coupling hole222aof the cover extended part222and the third coupling hole232aof the second housing cover230are vertically aligned. The cover extended part222of the first housing cover220is placed on the housing extended part212and the second housing cover230comes into contact with the cover extended part222of the first housing cover220, and as shown inFIG.11, the first coupling hole212a, the second coupling hole222aand the third coupling hole232aplaced in alignment are coupled together by inserting a nut N into the bolt B passing through them.

Meanwhile, the second housing cover230may have the same shape and structure as the first housing cover220. In this instance, the first housing cover220and the second housing cover230are coupled upside down. That is, when the first housing cover220and the second housing cover230are coupled to each other, the cover receiving part221of the first housing cover220is recessed down, and the receiving part221of the second housing cover230is recessed up. Additionally, the gas outlet H2of the second housing cover230is disposed opposite the gas inlet H1of the first housing cover220along the widthwise direction (Y axis direction) of the battery module1. As described above, the first housing cover220and the second housing cover230may be in 180° rotation symmetry, and accordingly, the cover receiving parts221may be coupled to each other with the cover extended parts222in contact with each other.

In any cases, when the first housing cover220and the second housing cover230are coupled, a space for receiving gas and flames entering through the gas inlet H1from the lower housing210is provided between the first housing cover220and the second housing cover230. The gas and flames entering the space passes through the exhaust path P formed by the variable partition structure400using hinges as described below, and in this process, the flame ceases to exist and the gas exits the battery module1through the gas outlet H2, and the internal pressure of the battery module1may reduce.

The variable partition structure400using hinges will be described in more detail with reference toFIGS.12to17in addition toFIGS.2and8.

As shown inFIGS.2and8, the variable partition structure400using hinges is installed in a gas receiving space formed between the first housing cover220and the second housing cover230and partitions the gas receiving space to define the gas exhaust path P. The variable partition structure400using hinges increases the movement path of flames that occur in the sub module100and enter the gas receiving space through the gas inlet H1together with gas. When the variable partition structure400using hinges is provided to allow the flames to move in a zigzag or spiral shape to prevent the flames from directly moving out through the gas outlet H2, the flames may not be let out and may cease to exist in the gas receiving space. The variable partition structure400using hinges may be installed across the cover receiving part221along the lengthwise direction (X axis direction) and/or the widthwise direction (Y axis direction) of the first housing cover220. In this embodiment, a plurality of variable partition structures400using hinges installed across the cover receiving part221along the lengthwise direction (X axis direction) of the first housing cover220is taken as an example.

The plurality of variable partition structures400using hinges may be installed at a predetermined interval along the widthwise direction (Y axis direction) of the first housing cover220and the second housing cover230. In this embodiment, the variable partition structures400using hinges are shorter than the length of the cover receiving part221, and some of them have one end of the lengthwise direction inserted into the left insertion groove221aand fixed into the cover receiving part221and the others have the other end of the lengthwise direction inserted into the right insertion groove221aand fixed into the cover receiving part221.

The variable partition structure400using hinges having one end of the lengthwise direction inserted into the left insertion groove221aand the variable partition structure400using hinges having the other end of the lengthwise direction inserted into the right insertion groove221aare installed in an alternating manner at a predetermined interval along the widthwise direction (Y axis direction) of the first housing cover220and the second housing cover230and partitions the gas receiving space between the first housing cover220and the second housing cover230to allow gas to move in a zigzag manner.

Referring toFIGS.12to17, the variable partition structure400using hinges includes at least one hinge structure410and at least two partition structures420.

As shown inFIG.12, the hinge structure410includes a hinge axis412that may be placed in the Z axis direction and a hinge cap414that is inserted and fixed to two ends of the hinge axis412. The two partition structures420are coupled rotatably around the hinge axis412. It is hinge coupling. The hinge axis412is in the shape of a cylindrical rod so that the two partition structures420can rotate around the hinge axis412.

Referring toFIG.13, the partition structure420includes a body422in the shape of a small plate, and a first handle structure424at one end of the body422and a second handle structure426at the other end. The first handle structure424has a groove through which the hinge axis412vertically passes, and the second handle structure426has two grooves through which the hinge axis412vertically passes. The groove through which the hinge axis412vertically passes has a circular shape having the inner diameter that is similar to the outer diameter of the cylindrical rod shaped hinge axis412. The first handle structure424and the second handle structure426have a circular periphery defining the circular groove.

FIGS.14to16are diagrams showing a process of assembling one hinge structure and two partition structures into a unit structure.

First, as shown inFIG.14, the second handle structure426of any one partition structure420and the first handle structure424of the other partition structure420are put together. Accordingly, the grooves through which the hinge axis412passes are vertically aligned. Subsequently, the partition structures420are assembled by inserting the hinge axis412into the grooves. Subsequently, when the hinge caps414are inserted and fixed to the two ends of the hinge axis412, a stable unit structure is formed without the hinge axis412slipping out of the grooves. The two partition structures420can rotate around the hinge axis412without slipping out of the hinge axis412in the presence of the hinge caps414.

Since the unit structure defining the exhaust path is formed using only three components (one hinge structure410and two partition structures420), it is very easy to assemble and standardization and simplification are achieved.

A necessary number of unit structures may be additionally connected by repeating the above-described process a desired number of times. For example, the variable partition structures400using hinges may be provided a little shorter than the length of the cover receiving part221as shown inFIG.17.

The variable partition structure400using hinges used in the present disclosure may be formed by standardizing the hinge structure410and the partition structure420and assembling desired number of hinge structures410and partition structures420. It is possible to adjust the length of the variable partition structures400using hinges by increasing and decreasing the number of hinge structures410and partition structures420. Additionally, since the partition structure420can rotate to the left and right around the hinge axis412, it is possible to arrange the partition structures420in the horizontal or vertical direction as desired. Accordingly, it is possible to freely adjust the movement paths of gas and flames occurred in the battery module, thereby easily adjusting the length of the exhaust paths of gas and flames by a simple task without needing to replace the module housing even if there are changes in the applied voltage and capacity of the battery cell. It is possible to achieve scalability depending on the type of the battery module and make mass production easy.

FIG.18is a diagram showing the gas movement path P in the battery module1.

Referring toFIG.18, the first handle structure424or the second handle structure426of the partition structure420is inserted or fixed to the insertion groove221aformed in the first housing cover220. The insertion groove221ahas a circular groove shape to conform to the shape of the periphery of the first handle structure424or the second handle structure426, and the body422of the partition structure420runs from the side toward the cover receiving part221. When the first handle structure424or the second handle structure426of the partition structure420is inserted into the insertion groove221ain the downward direction (i.e., in the Z axis direction), the first handle structure424or the second handle structure426of the partition structure420cannot slip out of the side of the insertion groove221aand is fixed in place.

The cover receiving part221of the first housing cover220has the grooves221bin horizontal and vertical grid shapes and the grooves221cat the intersections of the grid shapes. The partition structure420is received in the groove221b, and the hinge structure410is received in the groove221c. The groove221cthat receives the hinge structure410is a groove of a circular shape to conform to the X-Y plane projected shape of the hinge cap414of the hinge structure410. The groove221bthat receives the partition structure420is a groove of a rectangular shape to conform to the X-Y plane projected shape of the body422of the partition structure420. In case that the hinge cap414and the body422of the partition structure420have different X-Y plane projected shapes, the shape of the groove221bthat receives the partition structure420and the groove221cthat receives the hinge structure410may change accordingly.

As described above, the cover receiving part221has the plurality of insertion grooves221afor inserting/fixing the variable partition structures400using hinges on the periphery of the inner side wall thereof. Additionally, the cover receiving part221has the grooves221b,221cinto which the partition structures420using hinges are inserted. The plurality of insertion grooves221aand the plurality of grooves221b,221cmay be provided, and only some of them may be used to insert/fix the variable partition structures400using hinges. The designer may implement the variable partition structure400using hinges to form various flame exhaust paths by selecting some of the plurality of insertion grooves221aand the plurality of grooves221b,221c.

The partition structures420are inserted into some of the grooves221band are not inserted into the others. The flames are blocked by the partition structures420and pass through the grooves into which the partition structures420are not inserted.

There are some of the grooves221binto which the partition structures420are not inserted, and the open grooves221bform the exhaust path P along which gas and flames move. In this embodiment, the sparsely arranged variable partition structures400using hinges are taken as an example, so that the flame entering together with gas that occurs in the sub module100and enters the gas receiving space through the gas inlet H1of the first housing cover220does not directly exit through the gas outlet H2of the second housing cover230, and allow flames to move a long distance in a zigzag shape within the gas receiving space. The flames entering with the gas are arrested in the exhaust path P to prevent the flames from moving out. Only gas is forced out through the gas outlet H2, thereby ensuring safety.

Meanwhile, referring toFIGS.19and20, the battery module1according to an embodiment of the present disclosure may effectively prevent flames from moving out while smoothly expelling gas occurred in the sub module100by changing the number and array of variable partition structures400using hinges as necessary.

The partition structure420also plays a role of a stiff structure as a bead, and an appropriate number may be selected in the trade off relationship between stiffness suppression and material cost. For example, in the case ofFIG.18, due to the large explosion, a large number of variable partition structures400using hinges (for example, 7) is used to increase the strength though the material cost is high.

InFIG.19, the number of variable partition structures400using hinges is smaller than that ofFIG.18(for example, 3). When explosion is small, the number of variable partition structures400using hinges needed may reduce, thereby reducing the material cost. Accordingly, it is possible to reduce the cost by using a small number of variable partition structures400using hinges as shown inFIG.19. When explosion is moderate, it is possible to achieve a proper material cost and strength by using an intermediate number of variable partition structures400using hinges betweenFIGS.18and19.

Meanwhile,FIGS.18and19show that the exhaust path P directs flames toward one of the corner areas of the second housing cover, i.e., one edge, and as shown inFIG.20, the exhaust path P′ may direct flames toward the center of the second housing cover. Although the number of variable partition structures400using hinges is 1, the partition structure420changes the direction by 90° bend in the left counterclockwise direction at each corner area. In this instance, the gas outlet is provided at the center of the second housing cover230. The variable partition structure400using hinges according to the present disclosure can change the direction of the partition structure420with respect to the hinge axis412, so it is very useful for directing flames in a desired direction.

Meanwhile, a battery pack according to the present disclosure includes at least one battery module according to the present disclosure as described above.FIG.21is a schematic diagram showing the battery pack500according to an embodiment of the present disclosure.

Referring toFIG.21, the battery pack500may include at least one battery module1according to the previous embodiment and a pack case510to package the at least one battery module1. In addition to the battery module1and the pack case510, the battery pack500according to an embodiment of the present disclosure may further include various types of devices for controlling the charge/discharge of the battery module1, for example, a Battery Management System (BMS), a current sensor and a fuse. Since the battery pack500includes the battery module1, the battery pack500may be used as a battery pack having the feature and effect of the battery module1.

Additionally, a vehicle and/or an energy storage system (ESS) according to the present disclosure includes at least one battery pack of the present disclosure as described above.

FIG.22is a schematic diagram showing the vehicle600including the battery pack500according to an embodiment of the present disclosure.

Referring toFIG.22, the vehicle600may include the battery pack500according to an embodiment of the present disclosure, an Electronic Control Unit (ECU)610, an inverter620and a motor630. Preferably, the vehicle600may be an electric vehicle.

The battery pack500may be used as an electrical energy source that supplies power to the motor630to drive the vehicle600. The battery pack500may be charged or discharged by the inverter620by the operation of the motor630and/or an internal combustion engine (not shown). The battery pack500may be charged by a regenerative charging system coupled to a brake. The battery pack500may be electrically connected to the motor630of the vehicle600through the inverter620.

As described above, the battery pack500includes the BMS. The BMS estimates the condition of the cells in the battery pack500, and manages the battery pack500using the estimated condition information. For example, the BMS estimates and manages the condition information of the battery pack500such as State Of Charge (SOC), State Of Health (SOH), maximum allowable input/output power capacity and output voltage of the battery pack500. Additionally, the condition information may be used to control the charge or discharge of the battery pack500, and further, to predict when to replace the battery pack500.

The ECU610is an electronic control device that controls the condition of the vehicle600. For example, the ECU610determines torque information based on accelerator, brake and speed information, and controls the output of the motor630according to the torque information. Additionally, the ECU610transmits a control signal to the inverter620to charge or discharge the battery pack500based on the condition information such as the SOC and SOH of the battery pack500received from the BMS. The inverter620allows the battery pack500to be charged or discharged based on the control signal of the ECU610. The motor630drives the vehicle600based on the control information (for example, torque information) received from the ECU610using the electrical energy of the battery pack500.

The vehicle600includes the battery pack500, and the battery pack500includes the battery module1as described above and thus may increase the flame movement path. Accordingly, even if a problem occurs in the battery pack500while the vehicle600is driving, stability is maintained. Additionally, the battery pack500has high stability and can be used for a long time, and thus the vehicle600including the same is safety and easy to manage.

As well known, renewable energy, for example, solar energy and wind power, is difficult to produce electricity at a desired time, so the ESS stores renewable energy for use when necessary. To construct a single system for storing a few hundreds of kWh or higher of power, the ESS may use the battery pack according to the present disclosure to store the power. The battery pack according to the present disclosure includes the battery module according to the present disclosure as described above and thus may increase the flame movement path. Accordingly, even though a failure occurs in a certain battery pack, it is possible to keep the ESS stable and prevent a fire from spreading.

While the present disclosure has been hereinabove described with regard to a limited number of embodiments and drawings, the present disclosure is not limited thereto and it is obvious to those skilled in the art that a variety of modifications and changes may be made thereto without departing from the technical aspect of the present disclosure and the equivalent scope of the appended claims.