TW201737526A - Battery module and method for manufacturing the same - Google Patents

Abstract

In a battery module, a plurality of cells is placed in at least one battery holder. An encapsulation layer is disposed in the at least one battery holder, and filled in the gap between the cells. At least one insulating plate is disposed on the outer side surface of the at least one battery holder, and a plurality of conductive sheet is sandwiched between the at least one insulating plate and the outer side surface. The at least one insulating plate and the at least one battery holder together define an enclosed space having an opening, and the encapsulating layer is formed by hardening a curable liquid after the curable liquid is injected from an opening into the enclosed space.

Description

Battery module and method of manufacturing same

The present invention relates to a battery module, and more particularly to a battery module that prevents an abnormality from occurring continuously.

With the advancement of technology, transportation vehicles have evolved from using gasoline as a fuel for gasoline and locomotives to using natural gas as fuel for automobiles. As a power supply for steam and locomotives, steam and locomotives have been used, and bicycles have traditionally been driven by human resources. The machine acts as a power source for the bicycle to operate. Of course, with the gradual reduction of fuel raw materials, rising prices, and rising awareness of environmental protection, vehicles such as electric bicycles, electric locomotives, and electric vehicles have been developed. However, with the development of transportation vehicles and the importance of electric transportation vehicles facing the green energy industry, battery modules that provide transportation vehicle power have become an important component.

Figure 1 shows a conventional battery module. As shown in FIG. 1 , the battery module 100 includes a plurality of battery devices 110 , a circuit board 120 , and a plurality of voltage lines 130 and at least one connector 131 . Each battery device 110 includes a plurality of battery cells 111 and two electrode sheets 112. The battery cells 111 in a battery device 110 After the electrode sheets 112 are connected in series or in parallel, they are connected in series or in parallel with the other battery devices 110 to form the entire battery module 100.

If an abnormality occurs in the battery cell 111 in one of the battery devices 110, an abnormality may occur in the other adjacent battery cells 111, and such continuous abnormality may further cause an abnormality in the entire battery module 100.

In addition, in order to detect whether the voltage of each battery device 110 is abnormal in the battery module 100, as shown in FIG. 1, in the past, a pin 113 of the electrode pad 112 of each battery device 110 is used for welding or lap welding. At a voltage line 130, the other end of each voltage line is connected to a connector 131 to form a row of wires. The connector 131 is then plugged into another connector on the circuit board 120. The circuit board 120 is provided with a voltage detecting unit and a chip set (IC). With the above design, the voltage of each battery device 110 can be collected into the voltage detecting unit of the circuit board 120, and the voltage detecting unit can further transmit the voltage values to the chipset (IC) through the circuit of the circuit board 120. To monitor these voltages.

According to the conventional technique, although the voltage of each of the battery devices 110 can be monitored, when the battery cells 111 are abnormal, the abnormal battery cells 111 cannot be prevented, and the other battery cells 111 are abnormal.

Therefore, in addition to monitoring abnormalities, there is a need for a battery module 111 that effectively prevents an abnormality from occurring, and that affects the structure of the battery module 100 in which the battery cells 111 that do not have an abnormality are improved.

An object of the present invention is to provide a battery module and a method of manufacturing the same. Another object of the present invention is to provide a battery module having an encapsulation layer filled in a gap between a plurality of battery cells; and a method of manufacturing the same. Another object of the present invention is to provide a battery module that prevents abnormal occurrences and a method of manufacturing the same.

According to an embodiment of the invention, a battery module includes at least one battery holder, a plurality of battery cells, an encapsulation layer, a plurality of conductive sheets, and at least one insulating sheet. The battery cells are placed in the at least one battery holder. An encapsulation layer is disposed in the at least one battery holder and filled in a gap between the battery cells. The conductive sheets are disposed on an outer side of the at least one battery holder, and the battery cores are electrically connected. At least one insulating plate is disposed on an outer side of the at least one battery holder, and the conductive sheets are sandwiched between the at least one insulating plate and the outer side. The at least one insulating plate and the at least one battery holder collectively define a sealed space having an opening, and the encapsulating layer is formed by injecting a curable liquid, such as a liquid resin, into the sealed space from the opening and hardening.

In one embodiment, the at least one battery holder includes a first battery holder and a second battery holder that are connected to each other. The inner sides of the first battery holder and the second battery holder are each provided with a plurality of fixing bases. Both ends of the core are loaded into the fixing brackets of the first battery holder and the second battery holder. The conductive sheets are divided into a plurality of first conductive sheets and a plurality of second conductive sheets, and the first conductive sheets are disposed on an outer side of the first battery holder, and the second conductive sheets are disposed in the second The outer side of the battery holder. The at least one insulating plate comprises a first insulating plate and a second insulating plate, first The first conductive sheet is sandwiched between the first insulating sheet and the outer side of the first battery holder, and the second conductive sheets are sandwiched between the second insulating sheet and Between the outer sides of the second battery holder.

In one embodiment, the battery module further includes a plurality of sealing materials disposed at a first end of the battery cells for sealing a gap between the first end of the battery cells and the fixing base.

In one embodiment, the battery module further includes a sealing material sandwiched between the first battery holder and the connecting wall of the second battery holder, so that the first battery holder and the second battery holder The connection between the two is close.

In an embodiment, the battery module further includes a casing for accommodating the first battery bracket and the second battery bracket.

According to an embodiment of the invention, a method of fabricating a battery module includes the following steps. Providing a battery assembly structure, the battery assembly structure comprising at least one battery holder; a plurality of battery cells disposed in the at least one battery holder; a plurality of conductive sheets disposed on an outer side of the at least one battery holder, and the The battery core is electrically connected; and at least one insulating plate is disposed on the outer side of the at least one battery holder, and the conductive sheets are sandwiched between the at least one insulating plate and the outer side surface, wherein the at least one insulating plate and The at least one battery holder collectively defines a confined space having an opening. A curable liquid such as a liquid resin is poured into the sealed space from the opening. And hardening the curable liquid to form an encapsulation layer.

In an embodiment, the step of providing a battery assembly structure includes: mounting a plurality of first conductive sheets of the conductive sheets on an outer side of a first battery holder of the at least one battery holder; The battery core is mounted on the first battery holder; the plurality of second conductive sheets of the conductive sheets and a second battery holder of the at least one battery holder, and the first battery with the battery cores disposed thereon The first battery holder and the second insulating board are respectively attached to the outer side of the first battery holder and the second battery holder, and the first battery holder is attached to the first battery holder The second battery holder, the first insulating plate and the second insulating plate form the sealed space having the opening. The step of pouring a curable liquid into the sealed space from the opening comprises: pouring the curable liquid into the sealed space formed by the assembled first battery holder and the second battery holder Specify the height. Moreover, the step of hardening the curable liquid to form an encapsulation layer comprises: after hardening the curable liquid to form the encapsulation layer, assembling a battery management system into the first battery holder and the second battery holder, The first battery holder and the second battery holder assembled with the battery management system are then mounted in a casing to form a battery module.

In an embodiment, the step of mounting a plurality of battery cells on the first battery holder includes: presetting a sealing material at a first end of the battery cells; and loading the battery cells into the battery cells The plurality of fixing seats on the inner side surface of the first battery holder, and the sealing material closely contacts the first end portion of the battery cells and a gap between the fixing blocks.

In an embodiment, the plurality of second conductive sheets and a second battery holder are placed The step of assembling the first battery holders of the battery cells includes: providing a sealing material and sandwiching the adhesive material between the first battery holder and the connecting wall of the second battery holder, thereby The joint between the first battery holder and the second battery holder is in close contact.

According to the invention, the structural strength of the product is strengthened by filling and sealing, and the sealing material is waterproof, so that the battery module can be waterproofed. Preferably, the sealing material has thermal conductivity, and the battery module can be made. The group has a better uniform temperature. Due to the simplicity of the process, the design can be adjusted according to different product specifications, and the design is better.

100‧‧‧ battery module

110‧‧‧ battery device

111‧‧‧ battery core

112‧‧‧electrode

113‧‧‧ pins

120‧‧‧ boards

130‧‧‧voltage line

131‧‧‧Connector

200‧‧‧ battery module

211‧‧‧ battery core

212‧‧‧Conductor

213‧‧‧Contained materials

214‧‧‧Conductor

221‧‧‧ battery holder

222‧‧‧ accommodating slots

223‧‧‧closed slot

224‧‧‧ fixed seat

231‧‧‧ battery holder

240‧‧‧Confined space

241‧‧‧Specified height

242‧‧‧Battery Management System

243‧‧‧Resin

243a‧‧‧Encapsulation layer

245‧‧‧Blocked materials

250‧‧‧ Shell

291‧‧‧Insulation board

292‧‧‧Insulation board

The invention will be more fully understood from the following detailed description and appended claims.

Figure 1 shows a conventional battery module.

2 is a schematic diagram showing one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

Figure 3 is a schematic illustration of one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

4 is a schematic diagram showing one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

Figure 5 is a schematic diagram showing one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

Figure 6 is a schematic diagram showing one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

Figure 7 is a schematic illustration of one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

Figure 8 is a schematic diagram showing one of the steps of a manufacturing process in accordance with an embodiment of the present invention.

FIG. 9 is a partial view showing a portion of a battery module according to an embodiment of the present invention when the battery holder is locked.

FIG. 10 is a partial cross-sectional view showing a state in which a battery cell of a battery module according to an embodiment of the present invention is inserted into a holder of a battery holder.

The invention will be described in detail with reference to the drawings in which the same reference numerals will be used to identify the same or similar elements of the plurality of views. It should be noted that the drawings should be viewed in the orientation direction of the labels.

Lithium-ion batteries are increasingly used in applications, and their applications in life are widespread, but related accidents are also increasing. Battery modules need to be tested for safety. Since the current status of light-duty vehicles has been widely used in the transportation industry, similar destructive projects require special design protection. The traditional battery module uses a plastic to fix the battery core, and there is a slight spacing between the two battery cells to avoid the risk of short-circuiting the contact between the two battery cells due to the damage of the insulation layer of the battery can body. However, when the battery core is short-circuited by itself or other factors, causing the battery core to generate high heat or even more serious abnormal conditions, the conventional battery module fixing method will cause the abnormal condition of the single battery core to affect another battery core, and finally may Causes the entire battery module to be dangerous.

In order to improve the problems of the prior art, according to an embodiment of the present invention, the structural strength improvement and the safety of the system thermal explosion are improved by different packaging materials. 2-8 are schematic diagrams showing the steps of a manufacturing process in accordance with an embodiment of the present invention. As shown in FIG. 2-8, an embodiment of the present invention The method of manufacturing the battery module 200 includes the following steps.

Step S02: A plurality of conductive sheets 212 are mounted on an outer side of a battery holder 221, as shown in FIG. In more detail, the outer surface of the battery holder 221 may define at least one receiving groove 222. The shape of the receiving groove 222 corresponds to the shape of the conductive piece 212, and the conductive piece 212 is received in the receiving groove 222. Inside. In an embodiment, the outer side of the battery holder 221 may further define at least one closed slot 223. The closed slot 223 receives an insulating plate 291 (as shown in FIG. 5 below), wherein the conductive sheet 212 has a depth greater than that of the closed slot. The depth of 223 is such that the conductive sheet 212 is sandwiched between the battery holder 221 and the insulating plate 291.

Step S04: A plurality of battery cells 211 are mounted on the battery holder 221 as shown in FIG. In an embodiment, the inner side of the battery holder 221 is provided with a fixing seat 224, and the battery core 211 is inserted into the fixing base 224. In an embodiment, after a sealing material 213 is preset on the positive terminal of each battery cell 211, the battery core 211 is placed in the fixing base 224 of the battery holder 221. Since the positive terminal of the battery cell 211 has a protective structure, the resin cannot flow into the positive terminal, or the resin may flow from the notch of the positive terminal, which may cause a failure of the protective structure. In the present embodiment, the sealing material 213 can tightly fit the gap between the positive electrode end portion of the battery cell 211 and the fixing seat 224 without allowing a liquid resin such as a heat-resistant liquid resin to flow into the fixing seat 224, thereby flowing into the battery. The positive terminal of the core 211. In an embodiment, the sealing material 213 is not required, and the shape and size of the space defined by the fixing base 224 is matched with the shape and size of one end of the battery core 211, so that the battery core 211 is mounted on the fixing base 224. After that, the battery cell 211 is in close contact with the fixing seat 224 to form a hermetic structure, so that the resin does not flow into the fixing seat 224, thereby preventing the resin from flowing into the positive electrode end.

Step S06: assembling the plurality of conductive sheets 214 and the other battery holder 231 on the other side; and the battery holder 221 in which the battery core 211 has been placed in the foregoing step, as shown in FIG. In one embodiment, the inner side of the other battery holder 231 is provided with a fixing seat (not shown), and the battery core 211 is inserted into the fixing seat. In an embodiment, after a sealing material 213 is preset at the positive end of each of the battery cells 211, the battery core 211 is placed in the battery holder 231. In an embodiment, the shape and size of the space defined by the fixing seat may be different from the shape and size of one end of the battery core 211, so that the battery core 211 is inserted into the fixing seat. After that, the battery core 211 is in close contact with the fixing seat to form a hermetic structure, and the resin is not allowed to flow into the fixing seat, thereby preventing the resin from flowing into the positive electrode end. In one embodiment, a contact material 245 is provided and the adhesive material 245 is sandwiched between the connection walls of the battery holders 221 and 231, so that the seam between the battery holders 221 and 231 is completely adhered.

Step S08: The battery holder 221 and the other battery holder 231 are locked, and the insulating board 291 and the other insulating board 292 are respectively attached to the two outer sides of the battery holder 221 and the other battery holder 231, so that the battery is The bracket 221, the other battery holder 231, the insulating plate 291, and the other insulating plate 292 form a sealed space 240 that is open upward, as shown in FIGS. 5 and 6. The insulating plates 291 and 292 may be a waterproof insulating and thermally conductive sheet, and the material thereof may be polyester film (MYLAR), graphite sheet or FORMAX material.

Step S10: in the sealed space 240 formed by the assembled battery holder 221 and the other battery holder 231, liquid resin is poured to a specified height 241, and liquid resin is filled in the batteries. In the gap between the cores, as shown in Figure 6. Preferably, the height of the liquid resin is not higher than the assembly surface of the battery management system 242 (BMS), so that the battery cells 211 are completely covered by the liquid resin, so that a battery core 211 is separated from Another adjacent battery cell 211 prevents an abnormality of another adjacent battery cell 211 from occurring when the battery cell 211 is abnormal. In addition, the liquid resin can also be added with different additives to achieve different functions. For example, the liquid resin can have a heat conduction function to increase the heat conduction effect.

Step S12: After the liquid resin 243 is hardened, an encapsulation layer 243a is formed, and the subsequent battery management system 242 is assembled in the battery holder 221 and the other battery holder 231, as shown in FIG. Preferably, battery management system 242 is positioned above the encapsulation layer 243a.

Step S14: The assembled battery structure of the foregoing step S12 is loaded into the outer casing 250 to form the battery module 200, as shown in FIG.

According to the present invention, the structural strength of the product is strengthened by means of a potting and sealing method. In one embodiment, the sealing material is waterproof, and the battery module can be waterproof. In one embodiment, the sealing material is made to have thermal conductivity, and the battery module can have better uniform temperature uniformity. In one embodiment, the liquid resin used in the potting method can be a heat resistant liquid resin. In addition, in order to achieve different functions, it is also possible to further add additives of different functions to the aforementioned liquid resin to produce different functions. Due to the simplicity of the process, the design can be adjusted according to different product specifications, and the design is better.

In an embodiment of the invention, a method of manufacturing the battery module 200 includes the following steps. Step S22: A liquid resin is placed in a mold and hardened to form an encapsulation layer 243a having a plurality of accommodating spaces for accommodating the plurality of battery cells 211. Step S24: The battery cells 211 are placed in the accommodating spaces. Step S26: A plurality of conductive sheets 214 are assembled on both sides of the encapsulation layer 243a for electrically connecting the two electrode ends of the battery cells 211. In an embodiment, step S26 further includes assembling the two battery holders 231 on both sides of the encapsulation layer 243a. Step S28: The assembled battery structure of the foregoing step S26 is loaded into the outer casing 250 to form the battery module 200, as shown in FIG.

According to an embodiment of the invention, a battery module 200 is provided. As shown in FIG. 2-8, the battery module 200 includes a plurality of battery cells 211, a pair of battery supports 221 and 231, a plurality of conductive sheets 212, a plurality of other conductive sheets 214, a battery management system 242, and a pair. Insulating plates 291 and 292, a plurality of battery cells 211, and an encapsulation layer 243a.

The battery holders 221 and 231 are locked together. The encapsulation layer 243a, the battery management system 242, and the battery cells 211 are all disposed between the battery holders 221 and 231. The insulating plate 291 and the conductive sheets 212 are disposed on the outer side of the battery holder 221 , and the conductive sheets 212 are sandwiched between the insulating plate 291 and the outer side of the battery holder 221 . The insulating plate 292 and the other conductive sheets 214 are disposed on the outer side of the battery holder 221 , and the other conductive sheets 214 are sandwiched between the insulating plate 292 and the outer side of the battery holder 231 . The battery cells 211 are electrically connected to the battery management system 242 through the conductive sheets 212 and the conductive sheets 214.

In an embodiment, the fixing base 224 has a hollow structure to expose both ends of the battery core 211. Further, as shown in FIG. 5, a plurality of weakened structures 293 are formed at appropriate positions of the insulating plates 291 and 292, more specifically, at positions corresponding to the both ends of the battery cells 211 of the insulating plates 291 and 292. When a battery cell 211 is abnormally heated and rapidly heated, the accommodating space formed by the encapsulating layer 243a generates a high voltage, and the weakened structure 293 is formed to allow gas or flame to escape from the weakened structure 293, thereby preventing The problem of heat flow reverse irrigation.

FIG. 9 is a partial view showing a portion of a battery module according to an embodiment of the present invention when the battery holder is locked. As shown in FIG. 9, in an embodiment, the battery module 200 may further include a contact material 245, which may be, for example, O-Ring or a sealant. The adhesive material 245 is sandwiched between the connection wall surfaces of the battery holders 221 and 231, so that the joint between the battery holders 221 and 231 is completely adhered without leaking the liquid resin from the seam. In an embodiment, instead of using the adhesive material 245, the two battery holders 221 and 231 may be directly joined to each other without leaking the liquid resin.

FIG. 10 is a partial cross-sectional view showing a state in which a battery cell of a battery module according to an embodiment of the present invention is inserted into a holder of a battery holder. As shown in FIG. 10, in an embodiment, the inner side of the battery holder 221 is provided with a fixing seat 224, and the battery core 211 is inserted into the fixing base 224. Moreover, the battery module 200 may further include a sealing material 213, and after the sealing material 213 is preset at the positive end of each of the battery cells 211, the battery core 211 is placed in the battery holder 221. Since the sealing material 213 can tightly seal the gap between the battery cell 211 and the fixing seat 224, the liquid resin does not flow into the fixing seat 224, and further flows into the positive electrode end of the battery cell 211. The sealing material 213 may be in the form of a sheet or a circle, or the material thereof may be a sealant. In addition, the sealing material 213 may be disposed on the battery core 211, or In the space in which the battery core 211 is housed in the fixing base 224. In an embodiment, the sealing material 213 of the battery cell 211 is, for example, a sealing rubber ring, and may be selected and used, and the battery core 211 is directly in close contact with the fixing base 224.

In this case, the product structure strength is improved and the system thermal explosion condition is improved by different packaging materials. The method of the invention is to enclose the insulating and heat conducting material through the high heat conducting material, reduce the difference of the battery temperature, strengthen the reliability of the product, and simultaneously improve the safety application requirement when the short circuit of the battery core is short-circuited.

Having described the invention in detail, it will be apparent that the same method can be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention. All such modifications as would be apparent to one of ordinary skill in the art are included in the scope of the claims.

211‧‧‧ battery core

221‧‧‧ battery holder

231‧‧‧ battery holder

291‧‧‧Insulation board

292‧‧‧Insulation board

Claims (10)

A battery module comprising: at least one battery holder; a plurality of battery cells disposed in the at least one battery holder; an encapsulation layer disposed in the at least one battery holder and filled in a gap between the battery cells a plurality of conductive sheets disposed on an outer side of the at least one battery holder and electrically connected to the battery cores; and at least one insulating plate disposed on the outer side of the at least one battery holder, and the conductive The sheet is sandwiched between the at least one insulating plate and the outer side surface of the at least one battery holder, wherein the at least one insulating plate and the at least one battery holder collectively define a sealed space having an opening, and the encapsulating layer It is formed by injecting a liquid resin into the sealed space from the opening and hardening it. The battery module of claim 1, wherein the at least one battery holder comprises a first battery holder and a second battery holder connected to each other, and the inner sides of the first battery holder and the second battery holder are disposed There are a plurality of fixing bases, and the two ends of the battery cells are respectively mounted in the fixing brackets of the first battery holder and the second battery holder, and the conductive sheets are divided into a plurality of first conductive sheets and a plurality of a second conductive sheet, wherein the first conductive sheets are disposed on an outer side of the first battery holder, and the second conductive sheets are disposed on an outer side of the second battery holder, the at least one insulating sheet includes a first An insulating plate and a second insulating plate, the first insulating plate is placed The first conductive sheet is sandwiched between the first insulating sheet and the outer side surface of the first battery holder, and the second conductive sheets are sandwiched between the second insulating sheet and Between the outer sides of the second battery holder. The battery module of claim 2, further comprising a plurality of sealing materials, wherein the sealing materials are disposed at a first end of the battery cells for sealing the first end of the battery cells and the fixing The gap between the seats. The battery module of claim 2, further comprising a sealing material sandwiched between the first battery holder and the connecting wall of the second battery holder, so that the first battery holder and The connection between the second battery holders is tight. The battery module of claim 2, further comprising a battery management system assembled in the first battery holder and the second battery holder. The battery module of claim 2, further comprising a housing for receiving the first battery holder and the second battery holder. A method for manufacturing a battery module, comprising: providing a battery assembly structure, the battery assembly structure comprising at least one battery holder; a plurality of battery cells disposed in the at least one battery holder; and a plurality of conductive sheets disposed on the at least one An outer side of the battery holder, and the battery cells are electrically connected; and at least one insulating plate is disposed on the outer side of the at least one battery holder, and the conductive sheets are sandwiched between the at least one insulating board and the outer side Between the at least one insulating plate and the at least one battery holder collectively defining a sealed space having an opening; pouring a liquid resin into the sealed space from the opening; and hardening the liquid resin to form a package Layers form a battery module. The method of manufacturing a battery module according to claim 7, wherein the step of providing a battery assembly structure comprises: mounting a plurality of first conductive sheets of the conductive sheets on a first one of the at least one battery holder An outer side of the battery holder; the battery core is mounted on the first battery holder; the plurality of second conductive sheets of the conductive sheets and a second battery holder of the at least one battery holder are placed The first battery holders of the battery cells are assembled together; and a first insulating board and a second portion of the at least one insulating board are respectively attached to the outer sides of the first battery holder and the second battery holder An insulating plate, wherein the first battery holder, the second battery holder, the first insulating plate and the second insulating plate form the sealed space having the opening, and the liquid resin is poured into the sealed space from the opening The step of: filling the liquid resin into a specified height in the sealed space formed by the assembled first battery holder and the second battery holder, and hardening the liquid resin to form an encapsulation layer form a battery module includes: after hardening the liquid resin to form the encapsulation layer, assembling a battery management system into the first battery holder and the second battery holder, and assembling the battery management system The first battery holder and the second battery holder are mounted in a casing to form the battery module. The method of manufacturing the battery module of claim 8, wherein the step of mounting the plurality of battery cells on the first battery holder comprises: Presetting a sealing material at a first end of the battery cells; inserting the battery cells into a plurality of fixing seats on an inner side surface of the first battery holder, and the sealing material is close to the battery cells The first end portion and the gap between the fixed seats. The method of manufacturing a battery module according to claim 8, wherein the step of assembling the plurality of second conductive sheets and a second battery holder with the first battery holder on which the battery cores are placed includes Providing a tight material and sandwiching the adhesive material between the first battery holder and the connecting wall of the second battery holder, thereby making a seam between the first battery holder and the second battery holder Close together.