KR102354936B1 - Method of Manufacturing Battery Module and Manufacturing Device of Battery Module - Google Patents

Abstract

The present application relates to a method of manufacturing a battery module capable of shortening the manufacturing time of the battery module by shortening the curing time of the curable resin composition reversely discharged through an injection hole formed in the battery module. The present application also relates to an apparatus for manufacturing a battery module that can be applied to the method for manufacturing the battery module.

Description

Method of Manufacturing Battery Module and Manufacturing Device of Battery Module

The present application relates to a manufacturing method of a battery module and an apparatus for manufacturing a battery module applicable to the manufacturing method.

Secondary batteries are being used as power sources for energy storage systems (ESS), electric vehicles (EVs) or hybrid vehicles (HEVs) as well as small high-tech electronic devices such as mobile phones, PDAs, and notebook computers.

When a large amount of power is required, such as driving a motor of an electric vehicle, a large-capacity modular 　 battery pack configured by connecting a battery module including a plurality of high-output battery cells is generally used.

The battery cell may mean a unit capable of functioning as a secondary battery. The battery module may mean that the plurality of electrically connected battery cells are accommodated in a module case. The battery pack may be manufactured by attaching a plurality of battery modules to a base material to be detachable and electrically connecting the plurality of battery modules.

In order to fix the battery cells accommodated in the module case, the resin composition may be injected into the module case provided with the battery cells. The resin composition may use a heat-dissipating adhesive resin composition to fix the battery cell in the module case and to dissipate heat generated from the battery cell to the outside.

On the other hand, there was a problem in that the resin composition was over-injected into the battery module, or the resin composition injected into the battery module was reversely discharged through the injection port due to the increase in pressure inside the battery module after injection of the resin composition, and the reverse-discharged resin composition was removed. In order to do this, there was a problem in that it was necessary to wait for about 3 to 4 hours until the back-discharged resin composition was sufficiently cured. As a result, the manufacturing time for each battery module is prolonged, and there is a problem in that the productivity of the battery module is decreased.

Accordingly, there is a need for a method of manufacturing a battery module capable of shortening the manufacturing time of the battery module.

Korean Patent Publication No. 2016-0105354

An object of the present application is to provide a method of manufacturing a battery module capable of shortening the manufacturing time of the battery module by shortening the curing time of the curable resin composition reversely discharged through an injection hole formed in the battery module. Another object of the present application is to provide an apparatus for manufacturing a battery module that can be applied to the method for manufacturing the battery module.

Among the physical properties mentioned in this specification, when the measured temperature affects the result, unless otherwise specified, the corresponding physical property is a physical property measured at room temperature. The term ambient temperature is the natural temperature, either warmed or not reduced, usually any temperature within the range of about 10°C to 30°C, or on the order of about 23°C or about 25°C. In addition, unless otherwise specified in this specification, the unit of temperature is °C.

Among the physical properties mentioned in this specification, when the measured pressure affects the result, unless otherwise specified, the corresponding physical property is a physical property measured at normal pressure. The term atmospheric pressure refers to a natural temperature that has not been pressurized or depressurized, and usually about 1 atmosphere is referred to as atmospheric pressure.

This application relates to a method of manufacturing a battery module. A method of manufacturing a battery module according to the present application includes: injecting a curable resin composition through an injection hole formed on one surface of a battery module provided with a plurality of battery cells; and applying energy to the injection hole to cure the curable resin composition.

As an example, in the step of injecting the curable resin composition into the battery module, the battery module includes a battery module case and a battery cell. The battery cell may be accommodated in the module case. One or more battery cells may be present in the module case, and a plurality of battery cells may be accommodated in the module case. The number of cannery cells accommodated in the module case is not particularly limited as it is adjusted according to use and the like. The battery cells accommodated in the module case may be electrically connected to each other.

The module case may include at least a side wall and a lower plate that form an internal space in which the battery cell can be accommodated. In addition, the module case may further include an upper plate for sealing the inner space. The side wall, the lower plate, and the upper plate may be integrally formed with each other, or the module case may be formed by assembling the separate side walls, the lower plate, and/or the upper plate, respectively. The shape and size of the module case are not particularly limited, and may be appropriately selected depending on the purpose or the shape and number of battery cells accommodated in the inner space.

In the above, the terms upper plate and lower plate are terms of a relative concept used to distinguish between at least two plates constituting the module case. That is, it does not mean that the upper plate necessarily exists in the upper part and the lower plate necessarily exists in the lower part in an actual use state.

A hole may be formed in the lower plate, the side wall, and/or the upper plate of the module case. The hole may be an injection hole used to inject a material for forming the resin layer, that is, a curable resin composition, when the resin layer is formed by an injection process. The shape, number, and position of the holes may be adjusted in consideration of injection efficiency of the curable resin composition forming the resin layer. In one example, the hole may be formed in at least the lower plate and/or the upper plate.

The module case may be a thermally conductive case. The term thermally conductive case refers to a case having an overall thermal conductivity of 10 W/mk or more, or at least including a portion having the above-described thermal conductivity. For example, at least one of the aforementioned sidewall, lower plate, and upper plate may have the aforementioned thermal conductivity. In another example, at least one of the side wall, the lower plate, and the upper plate may include a portion having the thermal conductivity. For example, the battery module of the present application may include a first cured resin layer in contact with the upper plate and the battery cell, and a second cured resin layer in contact with the lower plate and the battery cell. Accordingly, it can be said that at least the lower plate may have thermal conductivity or include a thermally conductive portion.

a top plate, a bottom plate, and a side wall that are thermally conductive in the above; Or thermal conductivity of the region; in another example, about 20 W / mk or more, 30 W / mk or more, 40 W / mk or more, 50 W / mk or more, 60 W / mk or more, 70 W / mk or more, 80 W/mk or more, 90 W/mk or more, 100 W/mk or more, 110 W/mk or more, 120 W/mk or more, 130 W/mk or more, 140 W/mk or more, 150 W/mk or more, 160 W /mk or more, 170 W/mk or more, 180 W/mk or more, 190 W/mk or more, or about 195 W/mk or more. The higher the thermal conductivity, the more advantageous in terms of heat dissipation characteristics of the module, and the upper limit thereof is not particularly limited. In one example, the thermal conductivity is about 1,000 W/mK or less, 900 W/mk or less, 800 W/mk or less, 700 W/mk or less, 600 W/mk or less, 500 W/mk or less, 400 W/mk or less, 300 W/mk or about 250 W/mK or less, but is not limited thereto. The type of material exhibiting the above-described thermal conductivity is not particularly limited, and for example, a metal material such as aluminum, gold, silver, tungsten, copper, nickel, or platinum may be used. The module case may be entirely made of the thermally conductive material as described above, or at least a portion of the module case may be made of the thermally conductive material. Accordingly, the module case may have thermal conductivity within the above-mentioned range or may include at least one portion having the above-mentioned thermal conductivity.

In the module case, a portion having thermal conductivity within the above range may be a portion in contact with the resin layer and/or the insulating layer. In addition, the portion having the thermal conductivity may be a portion in contact with a cooling medium such as cooling water. In the case of having such a structure, heat generated from the battery cell can be effectively dissipated to the outside.

In the present application, the term battery cell refers to a single unit secondary battery including an electrode assembly and an exterior material.

The type of battery cell accommodated in the battery module case is not particularly limited, and all known various battery cells may be applied. In one example, the battery cell may be of a pouch type.

The curable resin composition injected through the injection hole formed in the battery module case may be, for example, an adhesive composition. The adhesive composition may include at least one selected from resin components known to be generally used as adhesives. Examples of the resin include an acrylic resin, a urethane resin, a silicone resin, and an epoxy resin. Among the resin components, it is known that an acrylic resin, a urethane resin, and a silicone resin have similar thermal conductivity to each other, an epoxy resin has superior thermal conductivity compared thereto, and an olefin resin has a higher thermal conductivity than an epoxy resin. Accordingly, resins having excellent thermal conductivity may be selected as needed. However, in general, it is difficult to ensure the desired thermal conductivity with only the resin component, and as will be described later, a method of including a filler component having excellent thermal conductivity in an appropriate ratio in the curable resin composition may be applied.

The curable resin composition may be a thermally conductive resin composition, and the cured product of the thermally conductive resin composition has a thermal conductivity of about 1.5 W/mK or more, 2 W/mK or more, 2.5 W/mK or more, 3 W/mK or more, 3.5 W/mK or greater or about 4 W/mK or greater. The thermal conductivity is about 50 W/mK or less, 45 W/mk or less, 40 W/mk or less, 35 W/mk or less, 30 W/mk or less, 25 W/mk or less, 20 W/mk or less, 15 W/ mk or less, 10 W/mK or less, 5 W/mK or less, 4.5 W/mK or less, or about 4.0 W/mK or less. As described above, when the curable resin composition is a thermally conductive resin composition, the lower plate into which the curable resin composition is injected may have a thermal conductivity of 10 W/mK or more. In this case, the portion of the module case showing the thermal conductivity may be a portion in contact with a cooling medium, for example, cooling water. Thermal conductivity of the thermally conductive resin composition is, for example, a value measured according to ASTM D5470 standard or ISO 22007-2 standard.

For example, after placing a cured product of the curable resin composition between two copper bars according to the standard of ASTM D 5470, one of the two copper bars is in contact with a heater, and the other is a cooler and After the contact is made, the heater maintains a constant temperature, and the capacity of the cooler is adjusted to create a thermal equilibrium state (a state showing a temperature change of about 0.1° C. or less in 5 minutes). The temperature of each copper rod is measured in a thermal equilibrium state, and the thermal conductivity (K, unit: W/mK) can be evaluated according to the following thermal conductivity equation. When evaluating thermal conductivity, the pressure applied ^{to the cured product can be adjusted to be about 11 Kg/25 cm 2} , and when the thickness of the cured product is changed during the measurement process, thermal conductivity can be calculated based on the final thickness.

<Thermal conductivity formula>

K = (QХdx)/(AХdT)

In the above formula, K is the thermal conductivity (W/mK), Q is the heat moved per unit time (unit: W), dx is the thickness of the cured product (unit: m), A is the cross-sectional area of the cured product (unit: m ² ), and dT is the temperature difference (unit: K) of the copper rod.

The method of making the thermal conductivity of the thermally conductive resin composition within the above range is not particularly limited. For example, the thermal conductivity of the thermally conductive resin composition can be adjusted by using a filler having thermal conductivity, which will be described later in the resin composition.

The curable resin composition may be, for example, a urethane resin composition. The urethane resin composition may include a main composition comprising at least a polyol or the like; and a curing agent composition including at least an isocyanate; may be a two-component type containing, and cured to form a cured resin layer.

As the urethane resin composition, at least as a polyol included in the main composition in order to secure the above physical properties, a resin composition including a polyol having a non-crystalline or sufficiently low crystallinity may be applied.

In the above, the term "amorphous" means a case in which the crystallization temperature (Tc) and the melting temperature (Tm) are not observed in the differential scanning 　 calorimetry (DSC) analysis to be described later, in which case the DSC analysis is 10 °C / min It can be carried out within the range of -80 °C to 60 °C at a rate of It can be measured by raising the temperature. In addition, "sufficiently low crystallinity" in the above means that the melting point (Tm) observed in the DSC analysis is about 20 °C or less, about 15 °C or less, about 10 °C or less, about 5 °C or less, about 0 It means a case of about °C or less, about -5 °C or less, about -10 °C or less, or about -20 °C or less. In the above, the lower limit of the melting point is not particularly limited, and for example, the melting point may be about -80 °C or more, about -75 °C or more, or about -70 °C or more.

When the polyol is crystalline or does not satisfy the above melting point range, when crystallinity is strong (at room temperature), the difference in viscosity according to temperature tends to increase, so the dispersion degree of the filler and the viscosity of the final mixture in the process of mixing the filler and the resin may have a detrimental effect on In addition, it may become difficult to satisfy physical properties such as cold resistance, heat resistance, and water resistance required in the curable resin composition for a battery module.

As the polyol, for example, a carboxylic acid polyol or a caprolactone polyol may be used.

The carboxylic acid polyol may be formed by reacting a component including a carboxylic acid and a polyol (eg, a diol or a triol), and the caprolactone polyol includes caprolactone and a polyol (eg, a diol or a triol). It can be formed by reacting the components. In this case, the carboxylic acid may be a dicarboxylic acid.

In one example, the polyol may be a polyol represented by the following Chemical Formula 1 or 2.

[Formula 1]

[Formula 2]

In Formulas 1 and 2, X is a unit derived from a carboxylic acid, and Y is a unit derived from a polyol. The unit derived from the polyol may be, for example, a triol unit or a diol unit. In addition, n and m may be any number, for example, n is a number within the range of 2 to 10, m is a number within the range of 1 to 10, A ₁ and A ₂ Each independently has 1 to 14 carbon atoms is alkylene within the range of

As used herein, the term “carboxylic acid-derived unit” may refer to a portion excluding a carboxyl group in a carboxylic acid compound. Similarly, as used herein, the term “polyol-derived unit” may refer to a portion of a polyol compound structure excluding a hydroxyl group.

That is, when the hydroxyl group of the polyol and the carboxyl group of the carboxylic acid react, water (H ₂ O) molecules are desorbed by the condensation reaction to form an ester bond. As such, when the carboxylic acid forms an ester bond by the condensation reaction, the carboxylic acid-derived unit may mean a portion of the carboxylic acid structure that does not participate in the condensation reaction. In addition, the polyol-derived unit may refer to a portion of the polyol structure that does not participate in the condensation reaction.

In addition, Y in Formula 2 also represents a portion excluding the ester bond after the polyol forms an ester bond with caprolactone. That is, when the polyol-derived unit, Y, in Formula 2 forms an ester bond between the polyol and caprolactone, it may mean a portion of the polyol structure that does not participate in the ester bond. The ester bonds are shown in Formulas 1 and 2, respectively.

On the other hand, when the polyol-derived unit of Y in the formula is a unit derived from a polyol including three or more hydroxyl groups, such as a triol unit, a branched structure may be implemented in the Y portion in the formula structure.

In Formula 1, the type of the carboxylic acid-derived unit of X is not particularly limited, but in order to secure desired physical properties, a fatty acid compound, an aromatic compound having two or more carboxyl groups, an alicyclic compound having two or more carboxyl groups, and 2 It may be a unit derived from at least one compound selected from the group consisting of aliphatic compounds having at least two carboxyl groups.

The aromatic compound having two or more carboxyl groups may be, for example, phthalic acid, isophthalic acid, terephthalic acid, trimellitic acid or tetrachlorophthalic acid.

The alicyclic compound having two or more carboxyl groups may be, for example, tetrahydrophthalic acid or hexahydrophthalic acid or tetrachlorophthalic acid.

In addition, the aliphatic compound having two or more carboxyl groups is, for example, oxalic acid, adipic acid, azelaic acid, sebacic acid, succinic acid, malic acid, glutaric acid, malonic acid, pimelic acid, suberic acid, 2,2-dimethyl succinic acid, 3,3-dimethylglutaric acid, 2,2-dimethylglutaric acid, maleic acid, fumaric acid or itaconic acid.

Considering the low glass transition temperature in the range to be described later, an aliphatic carboxylic acid-derived unit may be preferable rather than an aromatic carboxylic acid-derived unit.

On the other hand, in Formulas 1 and 2, the type of the polyol-derived unit of Y is not particularly limited, but in order to secure desired physical properties, from the group consisting of an alicyclic compound having two or more hydroxyl groups and an aliphatic compound having two or more hydroxyl groups may be derived from one or more selected compounds.

The alicyclic compound having two or more hydroxyl groups may be, for example, 1,3-cyclohexanedimethanol or 1,4-cyclohexanedimethanol.

In addition, the aliphatic compound having two or more hydroxyl groups is, for example, ethylene glycol, propylene glycol, 1,2-butylene glycol, 2,3-butylene glycol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, 1,2-ethylhexyldiol, 1,5-pentanediol, 1,9-nonanediol, 1,10-decanediol, glycerin or trimethylol It may be propane.

Meanwhile, in Formula 1, n is an arbitrary number, and the range may be selected in consideration of desired physical properties of the curable resin composition or the cured resin layer thereof. For example, n can be about 2 to 10 or 2 to 5.

In addition, in Formula 2, m is an arbitrary number, and the range may be selected in consideration of desired physical properties of a curable resin composition or a resin layer that is a cured product thereof. For example, m is about 1 to 10 or 1 to 5 can be

When n and m in Formulas 1 and 2 are out of the above ranges, the crystallinity of the polyol may be strengthened and adversely affect the injection processability of the composition.

In Formula 2, A ₁ and A ₂ are each independently alkylene having 1 to 14 carbon atoms. The number of carbon atoms may be selected in consideration of the desired physical properties of the curable resin composition or a resin layer that is a cured product thereof.

The molecular weight of the polyol may be adjusted in consideration of viscosity, durability, or adhesion, for example, in the range of about 300 to about 2,000. Unless otherwise specified, in the present specification, "molecular weight" may be a weight average molecular weight (Mw) measured using Gel Permeation Chromatograph (GPC). If out of the above range, the reliability of the resin layer after curing may be poor or problems related to volatile components may occur.

Meanwhile, the type of isocyanate included in the curing agent composition is not particularly limited, but a non-aromatic isocyanate compound not containing an aromatic group may be used to secure desired physical properties. When an aromatic isocyanate is used, it may be difficult to satisfy the load value and viscosity of the curable resin composition, which will be described later, because the reaction rate is too fast and the glass transition temperature may be high.

Examples of the non-aromatic isocyanate compound include aliphatic polyisocyanates such as hexamethylene diisocyanate, trimethylhexamethylene diisocyanate, lysine diisocyanate, norbornane diisocyanate methyl, ethylene diisocyanate, propylene diisocyanate or tetramethylene diisocyanate. ; alicyclic polyisocyanates such as transcyclohexane-1,4-diisocyanate, isophorone diisocyanate, bis(isocyanatemethyl)cyclohexane diisocyanate or dicyclohexylmethane diisocyanate; Or any one or more of the above-mentioned carbodiimide-modified polyisocyanate or isocyanurate-modified polyisocyanate; etc. may be used. Also, mixtures of two or more of the compounds listed above may be used.

The curable resin composition injected into the battery module may include a filler. The filler may be a thermally conductive filler. In the present application, the term thermally conductive filler refers to a material having a thermal conductivity of about 1 W/mK or more, about 5 W/mK or more, about 10 W/mK or more, or about 15 W/mK or more. The thermal conductivity of the thermally conductive filler may be about 400 W/mK or less, about 350 W/mK or less, or about 300 W/mK or less. The kind of thermally conductive filler that can be used is not particularly limited, and for example, aluminum oxide (alumina: Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), silicon nitride (Si ₃ N ₄ ), carbide Ceramic particles such as silicon (SiC) beryllium oxide (BeO), zinc oxide (ZnO), aluminum hydroxide (Al(OH) ₃ ), or boehmite may be used.

In addition to the above fillers, various types of fillers may be used. For example, in order to secure insulating properties of a resin layer that is a cured product of the curable resin composition, the use of a carbon filler such as graphite may be considered. Alternatively, fillers such as, for example, fumed silica, clay or calcium carbonate (CaCO ₃ ) may be used.

The form or ratio of the filler is not particularly limited, and the viscosity of the curable resin composition, the curing rate of the curable resin composition, the possibility of sedimentation in the cured resin layer of the curable resin composition, the desired thermal resistance or thermal conductivity, insulation, filling It may be appropriately adjusted in consideration of the effect, dispersibility or storage stability. In general, as the size of the filler increases, the viscosity of the composition including the same increases, and the possibility that the filler settles in the resin layer to be described later increases. Also, the smaller the size, the higher the thermal resistance tends to be. Therefore, in consideration of the above points, a filler of an appropriate type and size may be selected, and if necessary, two or more types of fillers may be used together. In addition, it is advantageous to use a spherical filler in consideration of the amount to be filled, but a filler in the form of needles or plates may also be used in consideration of network formation or conductivity.

In one example, the curable resin composition may use fillers having different average particle diameters. In the present application, the average particle diameter is the particle diameter (direct median) at 50% cumulative by volume of the particle size distribution. The point at which the cumulative value becomes 50% on the cumulative curve with the total volume as 100% after obtaining the particle size distribution on the volume basis. is the particle diameter of The average particle diameter (or D50) as described above may be measured by a laser diffraction method. Accordingly, the different average particle diameters may mean fillers having different particle diameters in 50% of the cumulative volume based on the particle size distribution. In one embodiment, fillers included in the curable resin composition may be mixed and used with at least three different average particle diameters.

The average particle diameter of the filler may be in the range of about 0.001 μm to about 100 μm. The average particle diameter of the filler may be about 0.01 μm or more, 0.1 μm or more, 0.5 μm or more, 1 μm or more, 2 μm or more, 3 μm or more, 4 μm or more, 5 μm or more, or about 6 μm or more in another example, 95 μm or less, 90 μm or less, 85 μm or less, 80 μm or less, 75 μm or less, 70 μm or less, 65 μm or less, 60 μm or less, 55 μm or less, 50 μm or less, 45 μm or less, 40 μm or less, 35 μm or less or less, 30 μm or less, 25 μm or less, 20 μm or less, 15 μm or less, or about 10 μm or less.

On the other hand, when using fillers having at least three different average particle diameters, consider the physical properties of the curable resin composition for fillers having three different average particle diameters among the fillers within the average particle diameter range, that is, from about 0.001 μm to about 100 μm. Therefore, it can be appropriately selected and used.

In order to obtain excellent heat dissipation performance, it may be considered that a high content of the thermally conductive filler is used. For example, it may be included in a ratio of about 70 parts by weight to 95 parts by weight relative to 100 parts by weight of the curable resin composition. As another example, the curable resin composition may be included in an amount of about 75 parts by weight or more, or about 80 parts by weight or more, and may be included in a ratio of about 90 parts by weight or less, based on 100 parts by weight of the curable resin composition.

When the content of the filler exceeds about 95 parts by weight based on 100 parts by weight of the curable resin composition, it is disadvantageous to satisfy the load value to be described later, and storage stability may deteriorate. On the other hand, if the amount of the filler is less than about 70 parts by weight relative to 100 parts by weight of the curable resin composition, the thermal conductivity is low, and thus a battery module to be described later including the same may be disadvantageous in securing the desired heat dissipation performance.

Since the filler is included in the curable resin composition in a ratio within the above range, overload occurrence of injection equipment can be improved and storage stability can be improved, and the cured product of the curable resin composition has high thermal conductivity, so the battery module including the same It is advantageous to secure heat dissipation performance.

Meanwhile, the moisture content of the filler may be about 1,000 ppm or less. The moisture content can be measured with a Karl Fischer titrator (KR831) under the conditions of 10% relative humidity and 5.0 or less drift. In this case, the moisture content may be an average moisture content with respect to all fillers used in the curable resin composition. A filler satisfying the above conditions may be selectively used, or after the filler to be used is dried in an oven at a temperature of about 200° C., the moisture content of the filler may be adjusted to satisfy the moisture content range. In another example, the upper limit of the moisture content of the filler may be about 800 ppm or less, 600 ppm or less, or about 400 ppm or less, and the lower limit thereof may be about 100 ppm or more or about 200 ppm or more.

The curable resin composition may contain a viscosity modifier, for example, a thixotropic agent, a diluent, a surface treatment agent or a coupling agent, etc. It may contain additional

The thixotropy imparting agent may adjust the viscosity according to the shear force of the curable resin composition so that the manufacturing process of the battery module may be more effectively performed. As the thixotropic agent that can be used, fumed silica and the like can be exemplified.

The diluent is generally used to lower the viscosity of the curable resin composition, and as long as it can exhibit the above action, various types of diluents known in the art can be used without limitation.

The surface treatment agent is for surface treatment of the filler included in the curable resin composition, and various types known in the art may be used without limitation as long as it can exhibit the above action.

In the case of the coupling agent, for example, it can be used to improve the dispersibility of the thermally conductive filler such as alumina, and if it can exhibit the above action, various types of known in the art can be used without limitation.

In addition, the curable resin composition may further include a flame retardant or a flame retardant auxiliary agent. In this case, a known flame retardant may be used without any particular limitation, for example, a flame retardant in the form of a solid filler or a liquid flame retardant may be applied. Examples of the flame retardant include organic flame retardants such as melamine cyanurate and inorganic flame retardants such as magnesium hydroxide. When the amount of the filler included in the curable resin composition is large, a liquid type flame retardant material (TEP, Triethyl phosphate or TCPP, tris(1,3-chloro-2-propyl)phosphate, etc.) may be used. In addition, a silane coupling agent capable of acting as a flame retardant synergist may be added.

The curable resin composition may include the configuration described above, and may be a solvent-based composition, an aqueous composition, or a solvent-free composition, but considering the convenience of the manufacturing process, the solvent-free type may be appropriate.

The method of manufacturing a battery module according to the present application includes applying energy to an injection hole formed on one surface of the battery module to cure the curable resin composition.

The energy applied to the injection hole is not particularly limited as long as it can cure the curable resin composition, and for example, heat, ultraviolet rays or infrared rays may be used.

As an example, the energy applied to the injection hole may be infrared.

In the present application, infrared means light having a wavelength in the range of 760 nm to 1 mm. Therefore, the energy applied to the injection hole may apply infrared rays having any wavelength among the wavelengths in the range of 760 nm to 1 mm.

Meanwhile, infrared rays having a wavelength within an appropriate range may be selected in consideration of the composition and curing rate of the curable resin composition. For example, when the above-described urethane resin composition is used as the curable resin composition, infrared rays applied from the energy applying unit may have a wavelength in the range of about 760 nm to 3,000 nm. If the wavelength range is shorter than 760 nm, the physical properties of the curable resin composition may be modified by the applied energy. On the other hand, if the wavelength range is longer than 3,000 nm, the curing efficiency of the curable resin composition may be deteriorated.

As an example, the range of the injection hole to which energy is applied is not particularly limited and may be appropriately adjusted in consideration of the size of the injection hole formed in the battery module, the range occupied by the reverse-discharged curable resin composition, and the like. For example, when the curable resin composition is reversely discharged through the injection hole due to being over-injected into the battery module through the injection hole, energy may be applied to the entire range occupied by the reverse-discharged resin composition.

As an example, the output of infrared rays applied to the inlet may be about 60% or more at 1 kW. In another example, it may be about 62% or more, 64% or more, about 66% or more, or less than about 80%.

As an example, the irradiation distance of infrared rays applied to the injection hole may be in the range of about 5 cm or more to less than 24 cm. As another example, the irradiation distance of infrared rays may be about 20 cm or less, 18 cm or less, or about 16 m or less, and may be about 5 cm or more or about 6 cm or more.

As an example, the irradiation time of infrared rays applied to the injection hole may be performed for about 30 seconds or more to less than about 120 seconds. In another example, the irradiation time of infrared rays applied to the inlet may be about 40 seconds or more, 50 seconds or more, or about 60 seconds or more, and may be about 85 seconds or less, 80 seconds or less, or about 75 seconds or less.

When the applied infrared output is 60% or less at 1 kW, when the infrared irradiation distance is 24 cm or more, or when the infrared irradiation time is less than about 30 seconds, the curing speed of the curable resin composition reversely discharged through the inlet is not sufficiently improved. Therefore, it is disadvantageous to shorten the manufacturing time of the battery module. On the other hand, when the applied infrared output is 80% or more at 1 kW, when the infrared irradiation distance is less than 5 cm, or when the infrared irradiation time exceeds about 120 seconds, the reversely discharged curable resin composition becomes a clay state or Bubbles may be generated, and thus the defective rate of the battery module may be increased.

When irradiating infrared rays to the curable resin composition reversely discharged through the inlet for an output of 60% or more at 1 kW, a distance of 5 cm or more to less than 24 cm, and a distance of 30 seconds or more to less than 120 seconds, the curing rate of the reverse-discharged curable resin composition It can be sufficiently improved, and thus the manufacturing time of the battery module can be shortened.

As an example, after applying energy to the injection hole, it may be left at room temperature for about 10 to 40 minutes. The term from about 10 minutes to 40 minutes means any time within the above range, and for example, about 10 minutes, about 15 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes after energy is applied to the inlet. or about 40 minutes.

If the time left at room temperature for less than about 10 minutes after applying energy to the injection hole, the reverse-discharged resin composition may not be sufficiently hardened to be removed from the battery module without leaving a residue.

After applying infrared rays having a wavelength range of 760 nm to 3,000 nm with an output of 60% or more at 1 kW, a distance of 5 cm or more to less than 24 cm, and 30 seconds or more to less than 120 seconds, leaving it at room temperature for about 10 to 40 minutes In this case, the reverse-discharged resin composition reaches a sufficiently hardened state to be removed from the battery module, and also, when the reverse-discharged resin composition is removed from the battery module, the surface of the battery module does not leave a residue on the surface of the battery module can be removed from In the present application, the meaning that the reverse-discharged curable resin composition is removed from the surface of the battery module without leaving a residue in the battery module is removed when the reverse-discharged curable resin composition is removed from the curable resin composition injected into the battery module. It may mean to be separated from the resin composition injected into the battery module without leaving a tail as if the part is drooping. 1 is an exemplary photograph showing a state in which a curable resin composition has been removed. The photograph on the left of FIG. 1 is an exemplary photograph showing a state in which the curable resin composition is removed without a residue, and the photograph on the right is an exemplary photograph illustrating a state in which the curable resin composition is removed leaving a residue.

As an example, the method of manufacturing a battery module according to the present application may include attaching an adhesive tape to an injection hole formed in the battery module before the step of injecting the curable resin composition.

The type and size of the adhesive tape are not particularly limited, and an appropriate adhesive tape may be selected from known adhesive tapes in consideration of the size or adhesive strength of the injection hole.

When the curable resin composition is injected into the battery module, the curable resin composition may be reversely discharged through the injection hole due to an overinjection into the battery module or an increase in pressure of the battery module. When the curable resin composition is reversely discharged, the battery module may be contaminated by the reverse-discharged resin composition.

By attaching the adhesive tape to the injection hole formed in the battery module, it is possible to prevent the battery module from being contaminated even when the curable resin composition is discharged back.

As an example, the method of manufacturing a battery module according to the present application may include peeling the adhesive tape attached to the injection hole formed in the battery module after the step of curing the curable resin composition by applying energy to the injection hole. .

If the curable resin composition is discharged back, it must be removed. At this time, by removing the tape attached to the injection hole after the step of curing the curable resin composition by applying energy to the injection hole, the reversely discharged resin composition can be more easily removed from the battery module.

The present application also relates to an apparatus for manufacturing a battery module.

An apparatus for manufacturing a battery module according to the present application includes: a chamber for accommodating a battery module having an injection hole capable of injecting a curable resin composition; and an energy applying unit that applies energy to an injection hole formed in the battery module.

As an example, the shape of the chamber part is not particularly limited, and may have an appropriate shape in consideration of the shape and size of the battery module accommodated. Further, the chamber portion may be of a closed type or an open type, or may be of an open/close type.

The sealed type may mean a form in which the internal space and the external space of the battery module manufacturing apparatus are cut off from each other. The open type may mean a form in which the internal space and the external space of the battery module manufacturing apparatus are not cut off from each other. The open/close type may refer to a form that can be adjusted so that the inner space and the outer space are not disconnected or disconnected.

An apparatus for manufacturing a battery module having a closed chamber part may be more advantageous than an apparatus for manufacturing a battery module having an open chamber part in controlling the internal temperature of the manufacturing apparatus and preventing contamination of the accommodated battery module. On the other hand, the manufacturing apparatus of the battery module having an open chamber part may have a shorter manufacturing time than the manufacturing apparatus of the battery module having a closed chamber part.

As an example, the apparatus for manufacturing a battery module includes an energy applying unit that applies energy to an injection hole formed in the battery module.

The same infrared ray as the above-described infrared ray may be applied to the energy applied by the energy applying unit.

Meanwhile, the location of the energy applying unit is not particularly limited as long as energy can be applied to the curable resin composition reversely discharged through the injection hole formed in the battery module. For example, when the injection hole formed in the battery module accommodated in the chamber unit faces upward, the energy applying unit may exist in the chamber unit at a position equal to that.

The energy applying unit may apply energy to an injection hole formed in the battery module to cure the curable resin composition reversely discharged through the injection hole. Accordingly, it is possible to shorten the manufacturing time of the battery module.

The manufacturing method of the battery module of the present application may shorten the curing time of the curable resin composition reversely discharged through the injection hole, and thus may shorten the manufacturing time of the battery module.

1 is an exemplary photograph showing a state in which a curable resin composition has been removed.

Hereinafter, the present application will be described in detail through Examples, but the scope of the present application is not limited by the Examples below.

Evaluation of the surface condition of the back-discharged curable resin composition

The surface state of the reverse-discharged curable resin composition of the battery module prepared in Examples and Comparative Examples was evaluated by visually observing.

[Evaluation standard]

When the back-discharged curable resin composition is not cured, is in a clay state, or bubbles are observed: ×

When the reverse-discharged curable resin composition is removed from the battery module without leaving a residue: ○

Example 1

Preparation of curable resin composition

Main resin: a caprolactone polyol represented by the following formula (2), wherein the number of repeating units (m in formula 2) is at a level of about 1 to 3, R ₁ and R ₂ are each alkylene having 4 carbon atoms, and a polyol As the derived unit (Y in Formula 3), a polyol including a 1,4-butanediol unit was used as the main resin.

[Formula 2]

Hardener: HDI (Hexamethylene diisocyanate) uretdione was used.

Filler: A first alumina filler having an average particle diameter of about 70 μm, a second alumina filler having an average particle diameter of about 20 μm, and a third alumina filler having an average particle diameter of about 2 μm were used. About 89 parts by weight of the filler based on 100 parts by weight of the curable resin composition was divided and blended in equal amounts to the main resin and the curing agent.

Main resin composition: The main resin and filler were prepared by mixing with a planetary mixer.

Curable resin composition: It was prepared by mixing the curing agent and the inorganic filler with a planetary mixer.

Curable resin composition: The prepared main resin composition and the curing agent composition are mixed with a mixer consisting of a cartridge and a static mixer so that the volume ratio of the main resin included in the main resin composition and the curing agent included in the curing agent composition is 1:1. A curable resin composition was prepared.

Manufacturing of battery modules

An adhesive tape (3M, 372KS) was attached to the injection hole formed in the lower plate of the battery module provided with a plurality of battery cells.

Then, the prepared curable resin composition was injected into the battery module through the adhesive tape attached to the injection hole.

Then, infrared rays having an output of about 70% at 1 kW, an irradiation distance of about 10 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 60 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and at room temperature for about 25 minutes was left in

Then, the adhesive tape attached to the inlet was removed to prepare a battery module.

Example 2

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 62% at 1kW, an irradiation distance of about 9 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 60 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Example 3

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 78% at 1 kW, an irradiation distance of about 9 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 60 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Example 4

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 70% at 1 kW, an irradiation distance of about 15 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 110 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Example 5

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 70% at 1 kW, an irradiation distance of about 5 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 35 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Comparative Example 1

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 30% at 1 kW, an irradiation distance of about 24 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 110 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Comparative Example 2

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 60% at 1 kW, an irradiation distance of about 24 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 180 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Comparative Example 3

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 80% at 1 kW, an irradiation distance of about 24 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 180 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Comparative Example 4

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 70% at 1 kW, an irradiation distance of about 9 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 180 seconds are irradiated to the curable resin composition reversely discharged through the injection hole, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Comparative Example 5

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 70% at 1 kW, an irradiation distance of about 9 cm, and a wavelength in the range of 760 nm to 3,000 nm for about 120 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Comparative Example 6

Preparation of curable resin composition

The same curable resin composition as Example 1 was used.

Manufacturing of battery modules

Infrared rays having an output of about 70% at 1 kW, an irradiation distance of about 9 cm and a wavelength in the range of 760 nm to 3,000 nm for about 60 seconds are irradiated to the curable resin composition reversely discharged through the inlet, and left at room temperature for about 25 minutes Except for one thing, a battery module was manufactured in the same manner as in Example.

Print
(%) investigation distance
(cm) investigation time
(candle) Reverse discharge surface condition evaluation Example 1 70 9 60 ○ Example 2 62 9 60 ○ Example 3 78 9 60 ○ Example 4 70 15 110 ○ Example 5 70 5 35 ○ Comparative Example 1 30 24 110 X (not cured) Comparative Example 2 60 24 180 X (not cured) Comparative Example 3 80 24 180 X (Clay state) Comparative Example 4 70 9 180 X (Bubble observation) Comparative Example 5 70 9 120 X (Bubble observation)

Claims (13)

injecting a curable resin composition through an injection hole formed on one surface of a battery module provided with a plurality of battery cells; and
and applying energy to the injection port to cure the curable resin composition,
The output of energy applied to the inlet is within the range of 60% or more and less than 80% at 1kW,
The irradiation distance of the energy applied to the inlet is in the range of 5 cm or more to less than 24 cm,
The irradiation time of the energy applied to the inlet is a method of manufacturing a battery module that is performed within the range of 30 seconds or more to less than 120 seconds. The method of claim 1 , wherein the curable resin composition includes a main resin, a curing agent, and a filler. The method of claim 2 , wherein the main resin includes at least one of a silicone resin, an acrylic resin, a polyol resin, and an epoxy resin. The method of claim 2 , wherein the main resin includes a polyol resin, and the curing agent includes an isocyanate. According to claim 2, wherein the filler is aluminum oxide (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), silicon nitride (Si ₃ N ₄ ), silicon carbide (SiC) beryllium oxide (BeO), zinc oxide (ZnO), aluminum hydroxide (Al(OH) ₃ ), boehmite (Boehmite), a method of manufacturing a battery module comprising a carbon filler or clay. The method of claim 1 , wherein the energy applied to the injection hole is infrared within a wavelength range of 760 nm to 3000 nm. delete delete delete The method of claim 1 , wherein after energy is applied to the inlet, the battery module is left at room temperature for a time in the range of 10 to 40 minutes. According to claim 1, wherein the method of manufacturing a battery module comprising the step of attaching an adhesive tape to the injection hole formed in the battery module before the step of injecting the curable resin composition. The method of claim 11 , further comprising peeling the adhesive tape attached to the injection hole formed in the battery module after the curing of the curable resin composition by applying energy to the injection hole. delete

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