BATTERY MODULE HAVING IMPROVED FASTENING OF COOLING PLATE USING REINFORCEMENT BEAM, AND BATTERY PACK COMPRISING SAME

Abstract

A battery module and a battery pack including same, have improved fastening of a cooling plate through the use of the combination of a reinforcement beam and welding in the fastening of the cooling plate, and thus detachment of the cooling plate due to swelling of a battery cell or due to external shocks is effectively prevented.

Claims

1. A battery module comprising: at least one battery cell; a module case having a receiving portion for accommodating the at least one battery cell therein; and a cooling plate formed at an external side of one surface of the module case, wherein the module case is fastened with the cooling plate by welding and a reinforcement beam.

2. The battery module of claim 1, wherein the cooling plate has a plate-shaped structure having a flexural structure for forming a fluid-move path.

3. The battery module of claim 1, wherein the cooling plate includes a fluid-move path at an inner side contacting the module case, wherein an outer peripheral surface at an opposite side of a surface contacting the module case has a flexural structure including a separation region spaced apart from the module case, and an adhesion region attached to the module case, and wherein the fastening by the welding and the reinforcement beam is formed at the adhesion region of the cooling plate.

4. The battery module of claim 1, wherein the reinforcement beam is fastened along an edge region of the cooling plate.

5. The battery module of claim 1, wherein a cross-section of the reinforcement beam has a H-shaped beam structure.

6. The battery module of claim 1, wherein in the welding, the module case is fastened with the cooling plate by a braze.

7. The battery module of claim 1, wherein the reinforcement beam penetrates one surface of each of the module case and the cooling plate, and wherein the welding is performed by filling an empty space between the reinforcement beam and each through hole of the module case and the cooling plate.

8. The battery module of claim 1, wherein the at least one battery cell is oriented in a direction perpendicular to the cooling plate.

9. The battery module of claim 1, wherein the module case includes: a U-shaped frame having a structure which covers a lower surface and opposite side surfaces of the receiving portion; and a top plate which covers an upper surface of the U-shaped frame.

10. The battery module of claim 9, wherein the module case includes a U-shaped frame having a structure which covers a lower surface and opposite side surfaces of the receiving portion, and wherein the cooling plate is fastened at an external side of the lower surface of the U-shaped frame.

11. The battery module of claim 1, wherein the module case includes: a bottom plate which forms a lower surface of the receiving portion; and a U-shaped frame having a structure which covers an upper surface and both side surfaces of the receiving portion, wherein the cooling plate is fastened at an external side of a lower surface of the bottom plate.

12. The battery module of claim 9, wherein the module case further includes an end plate which covers an open side surface of the U-shaped frame.

13. A battery pack comprising the battery module according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 is a cross-sectional view of a battery module showing a fastening structure of a conventional cooling plate.

[0029] FIG. 2 is a view showing a plane structure of a conventional cooling plate.

[0030] FIG. 3 is a cross-sectional view of a battery module showing a fastening structure of a cooling plate according to one embodiment of the present invention.

[0031] FIG. 4 is a view illustrating a plane structure of a cooling plate according to one embodiment of the present invention.

[0032] FIG. 5 is a perspective view of a battery module according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] As the inventive concept allows for various changes and numerous embodiments, particular embodiments will be illustrated in the drawings and described in detail in the text. However, this is not intended to limit the present invention to the specific form disclosed, and it should be understood to include all changes, equivalents, and substitutes included in the spirit and scope of the present invention.

[0034] In this application, it should be understood that terms such as “include” or “have” are intended to indicate that there is a feature, number, step, operation, component, part, or a combination thereof described on the specification, and they do not exclude in advance the possibility of the presence or addition of one or more other features or numbers, steps, operations, components, parts or combinations thereof. Also, when a portion such as a layer, a film, an area, a plate, etc. is referred to as being “on” another portion, this includes not only the case where the portion is “directly on” the another portion but also the case where further another portion is interposed therebetween. On the other hand, when a portion such as a layer, a film, an area, a plate, etc. is referred to as being “under” another portion, this includes not only the case where the portion is “directly under” the another portion but also the case where further another portion is interposed therebetween. In addition, to be disposed “on” in the present application may include the case disposed at the bottom as well as the top.

[0035] The present invention relates to a battery module, and the battery module includes a cooling plate fastened to one surface, and the cooling plate is fastened by using both welding and a reinforcement beam. In one example, a battery module according to the present invention includes: at least one battery cell; a module case having a receiving portion for accommodating the battery cell therein; and a cooling plate formed at an external side of one surface of the module case, wherein the module case is fastened with the cooling plate by welding or a reinforcement beam.

[0036] The module case is fastened to the cooling plate by a reinforcement beam which penetrates one surface of the module case and the cooling plate.

[0037] The present invention is characterized in that both welding and a reinforcement beam are used to fasten the module case with the cooling plate. In the past, the cooling plate was fastened with the module case using soldering, but in this case, the welded portion was damaged or separated. In addition, when the reinforcement beam is applied alone, it was difficult to implement the adhesion between the module case and the cooling plate. The present invention can strongly fasten the module case with the cooling plate by using a reinforcement beam and implement excellent adhesion through welding.

[0038] In one example, the reinforcement beam penetrates one surface of the module case and the cooling plate to be fastened. As a specific example, in the present invention, holes are formed on one surface of the module case and the cooling plate, and the reinforcement beam penetrates the holes. In addition, an empty space between the reinforcement beam and the holes of the module case and the cooling plate is filled by welding. As such, in the present invention, a dual fastening structure is formed between the module case and the cooling plate, and excellent airtightness can be implemented without being influenced by a change in external or internal conditions.

[0039] In one example, the cooling plate has a plate-shaped structure having a flexural structure for forming a fluid-move path. The cooling plate has a plate-shaped structure, and a flexural structure forming a flow path is formed in the plate-shaped structure. However, in the present invention, the shape of the cooling plate is not limited to a plate shape. For example, the cooling plate may be bent to cover 2 to 4 surfaces of the battery module. However, in order to minimize the increase in weight or volume due to the formation of the cooling plate or to implement cooling effects above a certain level, it is efficient to form a cooling plate of a plate-shaped structure on one surface of the battery module.

[0040] In one specific example, the cooling plate includes a fluid-move path at an inner side contacting the module case, an outer peripheral surface at an opposite side of a surface contacting the module case has a flexural structure including a separation region spaced apart from the module case, and an adhesion region closely attached to the module case, and the fastening by the welding and the reinforcement beam is formed at the adhesion region of the cooling plate. The cooling plate has a flexural structure by formation of a flow path, and a certain region, where a flow path is not formed, has an adhesion region, where a flexural structure is not formed, to be closely attached to the module case. The module case can be fastened with the cooling plate by applying welding and reinforcement beams to the adhesion region. Further, when the reinforcement beam is fastened on the adhesion region, it is possible to allow the fastened reinforcement beam not to protrude from the surface of the cooling plate.

[0041] In another specific example, the reinforcement beam is fastened along an edge region of the cooling plate. The position, where the reinforcement beam is fastened, is not particularly, limited, but it is advantageous to include the edge region of the cooling plate. For example, when the cooling plate has a plate structure of a quadrangle, the reinforcement beam can be formed along 4 sides.

[0042] For example, a cross-section of the reinforcement beam has a H-shaped beam structure. The module case is fastened with the cooling plate in a state that the reinforcement beam has penetrated the module case and the cooling plate. The central portion is narrow in width, and the upper and lower ends are wide in width. As such, the module case can be effectively fastened with the cooling plate using a H-shaped reinforcement beam.

[0043] In one example, in the welding, the module case is fastened with the cooling plate by a braze. In the present invention, the welding refers to any kind of metallurgical joining method of metal and includes all cases of joining two different materials by melting or heating metal materials. In the present invention, the welding includes brazing, welding, and/or soldering. Specifically, the welding can be performed in a brazing scheme. In the brazing, the base material and the filler material are joined by melting only the filler material without melting the base material by heating the joint. For example, in the brazing, filler materials are heated at a temperature of 450° C. or more. Only the filler materials are melted without melting the base materials, so that the two base materials may be joined by filling the narrow gap between the two base materials by using spreadability, wettability and capillarity of the melted metal.

[0044] In another example, the reinforcement beam penetrates one surface of the module case and the cooling plate to be fastened, and the welding is performed by filling an empty space between the reinforcement beam and each through hole of the module case and the cooling plate. In the present invention, the battery module is fastened with the cooling plate through a reinforcement beam, and the fastening is reinforced by welding. For example, the welding can be performed in a scheme such as brazing.

[0045] In one example, the battery cell is oriented in a direction perpendicular to the cooling plate and is accommodated in a receiving portion of the module case. If battery cells are accommodated in a direction parallel to the cooling plate, only the battery cells adjacent to the cooling plate are cooled intensively, and thus the temperature imbalance between battery cells in the battery module may be caused. In the present invention, by accommodating battery cells in a direction perpendicular to the cooling plate, it is possible to quickly cool battery cells through the interface between the battery cells while minimizing the temperature variation between the battery cells in the battery module.

[0046] In one specific example, the module case includes: a U-shaped frame having a structure which covers a lower surface and both side surfaces of the receiving portion; and a top plate which covers an upper surface of the U-shaped frame. For example, the module case includes a U-shaped frame having a structure which covers a lower surface and both side surfaces of the receiving portion, and the cooling plate is fastened at an external side of the lower surface of the U-shaped frame. The module case according to the present invention may have a frame having a structure surrounded by 4 surfaces. However, a structure having a top plate and a U-shaped frame is preferred in consideration of the convenience of accommodating battery cells and the easiness of joining the cooling plate.

[0047] In another specific example, the module case includes: a bottom plate which forms a lower surface of the receiving portion; and a U-shaped frame having a structure which covers an upper surface and both side surfaces of the receiving portion, wherein the cooling plate is fastened at an external side of the lower surface of the bottom plate. As another example of a module case according to the present invention, battery cells are positioned on the bottom plate, which is covered by a U-shaped frame. It is possible to be assembled in a form that a cooling plate is fastened on the outer surface of the lower portion of the bottom plate, and battery cells are accommodated at the inner side surface, which are then covered by a U-shaped frame.

[0048] In one example, the module case further includes an end plate which covers an end plate which covers an open side surface of the U-shaped frame. For example, an end plate having a PCM, etc. mounted thereon may be fastened on the open side surface of the U-shaped frame. The end plate may be formed on one or both surfaces.

[0049] The present invention further provides a battery pack including the above-described battery module. In one example, a battery pack according to the present invention includes at least one battery module described above; and a pack case for packaging the battery module. The battery pack is variously applicable as a power source of the vehicle. For example, it is applicable as a power source of a mild hybrid vehicle, a plug-in hybrid vehicle or an electric vehicle, etc.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] Hereinafter, the present invention will be described in more detail through drawings and the like. In describing the drawings, similar reference numerals are used for similar elements. In the accompanying drawings, the dimensions of the structures are shown in an enlarged scale for clarity of the invention. Terms such as “first” and “second” may be used to describe various components, but the components should not be limited by the terms. The terms are used only for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, a first component may be referred to as a second component, and similarly, the second component may also be referred to as the first component. Singular expressions include plural expressions unless the context clearly indicates otherwise.

First Embodiment

[0051] FIG. 3 is a cross-sectional view of a battery module showing a fastening structure of a cooling plate according to one embodiment of the present invention, and FIG. 4 is a view illustrating a plane structure of a cooling plate according to one embodiment of the present invention.

[0052] First, referring to FIG. 3, a battery module 100 according to the present invention includes: a plurality of battery cells 130; a module case having a receiving portion for accommodating the battery cells 130 therein; and a cooling plate 120 formed at an external side of one surface of the module case. The module case includes a U-shaped frame 111 and a top plate 112 which covers the open upper surface of the U-shaped frame 111. A plurality of battery cells 130 are accommodated in the receiving portion in the U-shaped frame 111, and buffer pads 131 are positioned between the battery cells 130 with a certain distance. The top surface 112 is fastened on the open upper surface of the U-shaped frame 111.

[0053] Further, the cooling plate 120 is fastened on the outer peripheral surface of the lower portion of the U-shaped frame 111. The outer peripheral surface of the lower portion of the U-shaped frame 111 is fastened with the cooling plate 120 by H-shaped reinforcement beams 121(a) and 121(b), and the fastened portion is filled by a braze.

[0054] Referring to FIG. 4, the shape of the cooling plate 120 and the positions where the reinforcement beams 121(a) to 121(e) are formed in the present invention are shown. Referring to FIG. 4, the cooling plate 120 is plate-shaped, and has a structure in which a flow path 122 for a fluid movement has been formed. The flow path 122 has a form surrounded by linear irregularities 123 and edge irregularities of the cooling plate 120, and dot-type irregularities 124 are formed at the region where the flow path is formed, to thereby supplement the mechanical strength.

[0055] The cooling plate 120 has a plate-shaped structure of 4 angles, reinforcement beams 121(a) to 121(d) are formed along 4 sides, respectively, and an additional reinforcement beam 121(e) is formed at the central portion. Each of the reinforcement beams 121(a) to 121(e) has a H-shaped beam structure. Herein, the central portion having a small width penetrates the bottom surface of the U-shaped frame 111 and the cooling plate 120, and both ends having a large width protrude from the front and rear sides of the penetrated regions.

[0056] Further, the portions fastened by the reinforcement beams 121(a) to 121(e) are filled by a braze so that there is no empty space. In the present invention, as the U-shaped frame 111 is fastened with the cooling plate using reinforcement beams 121(a) to 121(e), and the fastened portion is filled by a braze, the mechanical strength is reinforced, and the adhesion of the cooling plate 120 may be maintained even when there is an internal or external shock or a temperature change.

Second Embodiment

[0057] FIG. 5 is a perspective view of a battery module according to another embodiment of the present invention. Referring to FIG. 5, a battery module 200 according to the present invention has a structure in which a plurality of battery cells 230 are accommodated in a battery case, and a cooling plate 220 is fastened on the lower surface. The module case includes: a bottom plate 212 which forms a lower surface of a receiving portion; and a U-shaped frame 211 which covers the upper surface and both side surfaces of the receiving portion, and the cooling plate 220 is fastened at an external side of the lower surface of the bottom plate 212.

[0058] The cooling plate 220 is plate-shaped, and has a structure in which a flow path 222 for a fluid movement has been formed. The flow path 222 has a form surrounded by linear irregularities 223 and edge irregularities of the cooling plate 220, and dot-type irregularities 224 are formed at the region where the flow path is formed, to thereby supplement the mechanical strength.

[0059] The cooling plate 220 has a plate-shaped structure of 4 angles, and reinforcement beams 221(a) to 221(d) are formed along 4 sides, respectively. Each of the reinforcement beams 221(a) to 221(d) has a H-shaped beam structure. Herein, the central portion having a small width penetrates the bottom plate 211 and the cooling plate 220, and both ends having a large width protrude from the front and rear sides of the penetrated regions.

[0060] Further, the portions fastened by the reinforcement beams 221(a) to 221(d) are filled by a braze so that there is no empty space. By filling the fastened portion by a braze, the mechanical strength is reinforced, and the adhesion of the cooling plate 220 may be maintained even when there is an internal or external impact or a temperature change.

[0061] In the above, the present invention has been described in more detail through the drawings and examples. Accordingly, the embodiments described in the specification and the configurations described in the drawings are only the most preferred embodiments of the present invention, and do not represent all of the technical ideas of the present invention. It is to be understood that there may be various equivalents and variations in place of them at the time of filing the present application.

Description of Reference Numerals

[0062] 10, 100, 200: battery module

[0063] 11, 111, 211: U-shaped frame

[0064] 12, 112: top plate

[0065] 20, 120, 220: cooling plate

[0066] 21: welded portion

[0067] 22, 222: flow path

[0068] 123, 223: linear irregularities

[0069] 124, 224: dot-type irregularities

[0070] 30, 130, 230: battery cell

[0071] 31, 131: buffer pad

[0072] 121(a), 121(b), 121(c), 121(d), 121(e), 212(a), 212(b), 212(c), 212(d): reinforcement beam

[0073] 122: flow path

[0074] 212: bottom plate