US 20210351455A1

IN
( 19 ) United States
( 12 ) Kim
Patent
et al .
Application Publication ((4310)) Pub
Pub.. Date
No .: :US 2021/0351455 A1
Nov. 11 , 2021
(54) BATTERY CASE FOR ELECTRIC CAR Jul. 31 , 2019 ( KR ) 10-2019-0093142
Jul. 31 , 2019 ( KR ) 10-2019-0093143
( 71 ) Applicant: LG HAUSYS , LTD ., Seoul (KR) Publication Classification
( 72 ) Inventors: Do - Hyoung Kim , Seoul ( KR) ; (51 ) Int. CI .
HOM 10/6554 (2006.01 )
Hyun - Jin Choi , Seoul ( KR) ; BOOL 50/64 (2006.01 )
Kwon - Taek Kim , Seoul (KR) ; Ae - Ri B60L 50/60 (2006.01 )
Oh , Seoul (KR) ; Chan -Ho Jung, Seoul HOIM 10/613 (2006.01 )
( KR) ; Ha - Jeong Seo , Seoul ( KR) ; HOIM 10/625 (2006.01 )
Eun - Guk Lee , Seoul ( KR) ; Hee - June HOIM 10/6556 (2006.01 )
Kim , Seoul (KR) HOIM 50/204 (2006.01 )
(52) U.S. Ci.
(21 ) Appl. No.: 17 / 277,472 CPC HOIM 10/6554 ( 2015.04 ) ; B60L 50/64
(2019.02 ) ; B60L 50/66 (2019.02 ) ; HOTM
(22) PCT Filed : Sep. 20 , 2019 10/13 (2015.04 ) ; HOIM 2220/20 ( 2013.01 ) ;
HOIM 10/6556 ( 2015.04 ) ; HOIM 50/204
( 86 ) PCT No .: PCT/KR2019 /012305 (2021.01 ) ; B60Y 2200/91 (2013.01 ) ; HOLM
$ 371 (c ) ( 1 ) , 10/625 (2015.04 )
(2) Date: Mar. 18 , 2021
9 ( 57 ) ABSTRACT
Provided is a battery case for an electric car . The battery case
( 30 ) Foreign Application Priority Data includes a support part configured such that aa battery module
is seated and supported and including a sidewall extending
Sep. 20, 2018 ( KR ) 10-2018-0112780 upwards from an edge portion thereof, an inner frame
Sep. 20 , 2018 ( KR) 10-2018-0112781 coupled to a top surface of the support part to partition a seat
Sep. 21 , 2018 ( KR) 10-2018-0113401 part of the battery module, and an outer frame coupled to an
Jun . 28 , 2019 (KR ) 10-2019-0077888 outer surface of the support part.

150
130

200 240

300
330
360
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CA .
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.

320
-350

340

450
420
430

Q
--350
540
Patent Application Publication Nov. 11 , 2021 Sheet 1 of 30 US 2021/0351455 A1

FIG . 1
Patent Application Publication Nov. 11 , 2021 Sheet 2 of 30 US 2021/0351455 A1

FIG . 2

***
2

440

420
430

500

Com
OLO -150

540
Patent Application Publication Nov. 11 , 2021 Sheet 3 of 30 US 2021/0351455 A1

120
100
FIG . 3

140

240

30

350
a

)
400

420

OO O

540
Patent Application Publication Nov. 11 , 2021 Sheet 4 of 30 US 2021/0351455 A1

120

FIG . 4 130

200

330
360
350
S.
*****

ana

320
340
440
400ya

420

500

Com0 ???
o
550
Patent Application Publication Nov. 11 , 2021 Sheet 5 of 30 US 2021/0351455 A1

FIG . 5
400

100
410 440
0
0
120 0
0 110
450 150
130

140

420
430

FIG . 6

360
400

110
> 100
140
600
-200

450 370 300

Patent Application Publication Nov. 11 , 2021 Sheet 6 of 30 US 2021/0351455 A1

FIG . 7

200

376

FIG . 8 330
;

310 200 500

Patent Application Publication Nov. 11 , 2021 Sheet 7 of 30 US 2021/0351455 A1

FIG . 9

-130

600 600
?? 600
370 340
330 310
(a) 720
710
150

300
?? 310
600 370 340 350 600
(b)
Patent Application Publication Nov. 11 , 2021 Sheet 8 of 30 US 2021/0351455 A1

FIG . 10
200

300

360 310 ve**

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towe
320

O
0
Center o --550

540
Patent Application Publication Nov. 11 , 2021 Sheet 9 of 30 US 2021/0351455 A1

FIG. 11

200 240

300

360 310 C. ********

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-320
Patent Application Publication Nov. 11 , 2021 Sheet 10 of 30 US 2021/0351455 A1

FIG . 12
200 240
250

306
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+
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outlet11
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500
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FIG . 13
200
600

310
300
500
Patent Application Publication Nov. 11 , 2021 Sheet 11 of 30 US 2021/0351455 A1

FIG . 14

200

600
D2 T'S

300

500 TIT
311 312
BS X
310
Z

250 FIG . 15
712
200 -700

500

311 312
310
Patent Application Publication Nov. 11 ,9 2021 Sheet 12 of 30 US 2021/0351455 A1

FIG. 16 712

200
117 250 T 1 710

311 312

720
300

FIG.17
100
610
Patent Application Publication Nov. 11 , 2021 Sheet 13 of 30 US 2021/0351455 A1

150 152 FIG . 18

712
100
610 700
200
620
720

310 .
300
500

FIG . 19

ZZZ
150

V
610 AZZXX
250
200.
WZ

w 2
310
300
500
Patent Application Publication Nov. 11 , 2021 Sheet 14 of 30 US 2021/0351455 A1

FIG . 20
200
...

FIG . 21
200
600

310

500 ZA ZAA
FIG . 22
200
300 d
310

500 ? Z A
FIG . 23
100

300

500
Patent Application Publication Nov. 11 , 2021 Sheet 15 of 30 US 2021/0351455 A1

FIG . 24

600 700
???? 720

500

FIG . 25
BM
200

310
300
500

FIG . 26
BM

720

310
300
500
Patent Application Publication Nov. 11 , 2021 Sheet 16 of 30 US 2021/0351455 A1

FIG . 27

600

FIG . 28
301

30

302

FIG . 29
303

30

303
Patent Application Publication Nov. 11 , 2021 Sheet 17 of 30 US 2021/0351455 A1

FIG . 30
$ 110
Loadingmetal frame
$120
Laminating adhesive
$ 130
Loading FRP
?? $ 140
Heating and Pressing

FIG . 31

D ?

f 30
Patent Application Publication Nov. 11 , 2021 Sheet 18 of 30 US 2021/0351455 A1

FIG . 32

60

SO at
50 FIG . 33
51

t,

51
Patent Application Publication Nov. 11 , 2021 Sheet 19 of 30 US 2021/0351455 A1

FIG . 34
200 340 30 110 130 120

B
-B
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en

FIG . 35

-112
110
114
600

30
Patent Application Publication Nov. 11 , 2021 Sheet 20 of 30 US 2021/0351455 A1

FIG . 36
113
720
-700

( 112
::::: 600

ZZZ

30

120 FIG . 37
CZ 122

730
Patent Application Publication Nov. 11 , 2021 Sheet 21 of 30 US 2021/0351455 A1

FIG . 38

112
110
610 114
620

30 340

FIG . 39
113
720

?
610
620

30 340
Patent Application Publication Nov. 11 , 2021 Sheet 22 of 30 US 2021/0351455 A1

FIG . 40 100
200 340 30 110 130 120

d C
O
113

700

FIG . 41
113

116

600

30 340
Patent Application Publication Nov. 11 , 2021 Sheet 23 of 30 US 2021/0351455 A1

1000 FIG . 42
1110 1100 1200 FIG . 43
t 1200

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72 -1220

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12
FIG . 44
1200 1300
FIG . 45
E 1300

E
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1310
1600
1100
Patent Application Publication Nov. 11 , 2021 Sheet 24 of 30 US 2021/0351455 A1

FIG . 46
1200
1300
1100 1230 1240

1241 10 O
10 o

lo o

FIG . 47
-2100
1

-2200

2300
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-2400
Patent Application Publication Nov. 11 , 2021 Sheet 25 of 30 US 2021/0351455 A1

FIG . 48
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2500
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Patent Application Publication Nov. 11 , 2021 Sheet 26 of 30 US 2021/0351455 A1

FIG . 49
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Patent Application Publication Nov. 11 , 2021 Sheet 27 of 30 US 2021/0351455 A1

FIG . 52
3000

3200

3201
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Patent Application Publication Nov. 11 , 2021 Sheet 28 of 30 US 2021/0351455 A1

FIG . 53
3200

3201

3100

3200
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Patent Application Publication Nov. 11 , 2021 Sheet 29 of 30 US 2021/0351455 A1

FIG . 54
3000 3100

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Patent Application Publication Nov. 11 , 2021 Sheet 30 of 30 US 2021/0351455 A1

FIG . 55
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300 '

800

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500 '
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US 2021/0351455 Al Nov. 11 , 2021
1

BATTERY CASE FOR ELECTRIC CAR [ 0012 ] In an aspect , a battery case for an electric car may
include a cooling block configured such that a battery
BACKGROUND OF THE DISCLOSURE module is seated and supported, and including a sidewall
Field of the Disclosure
extending upwards from an edge portion thereof; an inner
frame coupled to a top surface of the support part to partition
[ 0001 ] The present disclosure relates to a battery case for a seat part of the battery module ; and an outer frame coupled
an electric car. to an outer surface of the support part.
[ 0013 ] The support part may be a cooling block having on
Related Art a top surface thereof an uneven cooling path .
[ 0002 ] Recently, as environmental issues become impor [ 0014 ] The inner frame and the outer frame may be spaced
tant, automobile industry undergoes substantial changes . apart from each other with the sidewall of the cooling block
Globally , the fuel efficiency regulation of vehicles becomes being interposed therebetween .
stricter. In order to cope with the stricter regulation, auto [ 0015 ] The cooling block may be made of a fiber- rein
mobile makers are developing the technology for reducing forced plastic composite , and the inner frame and the outer
the weight of components of a hybrid car, an electric car, and frame may be made of a material different from that of the
a vehicle . This technology is practically commercialized . cooling block .
[ 0003 ] In particular, as for the technical development for [ 0016 ] A heat dissipation plate may be coupled between
reducing the weight of electric -car components , a change in the inner frame and the cooling block .
material for a battery case which supports an electric - car [ 0017] The heat dissipation plate and the inner frame may
battery is required . In order to enhance productivity and be coupled to each other by an adhesive, the heat dissipation
durability, a change in coupling structure between respective plate and the cooling block may be coupled to each other by
components is required . the adhesive, and the cooling block and the outer frame may
[ 0004 ] That is , a conventional battery case is problematic be coupled to each other by the adhesive.
in that it is made of metal, so that the weight of a vehicle [ 0018 ] The inner frame may be coupled to an inside of the
body is increased . Furthermore , when the battery case is sidewall of the cooling block , and the outer frame may be
made of an aluminum material so as to reduce the weight of coupled to an outside of the sidewall of the cooling block .
the vehicle body, cost is undesirably increased because a [ 0019 ] The cooling block may further include a fastening
process of assembling the components constituting the bat hole to be fastened to the inner frame through a fastening
tery case adopts a welding process or the like . hole formed in the heat dissipation plate.
[ 0020 ] The cooling block may further include a spacer
SUMMARY formed around the fastening hole to protrude upwards.
[ 0005 ] The present disclosure provides a battery case for [ 0021 ] The outer frame may include a horizontal rib that
an electric car, in which a cooling path is formed , thus horizontally extends inwards to support a part of a bottom
securing heat conductivity and realizing a reduction in surface of the cooling block .
weight. [ 0022 ] The heat dissipation plate may be made of an
[ 0006 ] The present disclosure also provides a battery case aluminum material.
for an electric car, in which productivity is enhanced through [ 0023 ] The fiber - reinforced plastic composite may include
a convenient coupling structure between respective compo matrix resin and reinforced fiber in the form of long fiber or
nents . reinforced fiber in the form of fabric woven by continuous
[ 0007] The present disclosure also provides a battery case fiber.
for an electric car , in which durability is secured through a [ 0024 ] The battery case may further include a lower
robust assembly structure , and the stability of a battery protective plate coupled to a bottom of the cooling block .
module can be maintained even if external force is applied [ 0025 ] The lower protective plate may be made of a
due to a multilayered structure . fiber - reinforced plastic composite.
[ 0008 ] The present disclosure also provides a battery case [ 0026 ] The lower protective plate may include a protrud
for an electric car, in which it is possible to reduce an overall ing support part formed at a position corresponding to the
weight while satisfying mechanical performance . spacer of the cooling block to protrude, and a fastening hole
[ 0009 ] The present disclosure also provides a battery case formed at a position corresponding to the fastening hole of
for an electric car, in which water -tightness between an the cooling block , so that the lower protective plate may be
interior and an exterior of the battery case is excellent when fastened to the cooling block by a fastening member.
a battery module is mounted . [ 0027] The cooling block and the lower protective plate
[ 0010 ] The present disclosure also provides a battery case may be integrally formed .
for an electric car, in which a? reduction in weight is realized, [ 0028 ] In another aspect , a battery case for an electric car
the battery case can be safely and firmly protected, and it is may include a support part configured such that a battery
easy to replace some components when the battery case is module is seated and supported ; an inner frame coupled to
damaged . a top surface of the support part to partition a seat part of the
[ 0011 ] The present disclosure also provides a battery case battery module ; an outer frame coupled to an outer surface
for an electric car, in which a support layer of a battery case of the support part; and a lower protective plate coupled to
is formed by integrally injection molding two types of a bottom of the support part, wherein the lower protective
fiber -reinforced plastic composites , and a fastening member plate may include a sidewall formed on an edge portion
is subjected to injection molding together with the support thereof to extend upwards.
layer to couple the fastening member to the support layer, so [ 0029 ] The support part may be a cooling block having on
that robustness and productivity are enhanced . a top surface thereof an uneven cooling path .
US 2021/0351455 A1 Nov. 11 , 2021
2

( 0030 ) A heat dissipation plate made of a material having [ 0047 ] FIG . 3 is an exploded perspective view of the
high heat conductivity, such as aluminum , may be coupled battery case shown in FIG . 1 , in which the cooling path is not
between the inner frame and the cooling block . present and the heat dissipation plate is present in the
[ 0031 ] Each of the uneven inner frame and the outer frame cooling block.
may be made of a material having high stiffness, such as [ 0048 ] FIG . 4 is an exploded perspective view of the
steel , alloy, or a fiber- reinforced plastic composite . battery case shown in FIG . 1 , in which both the cooling path
[ 0032 ] The cooling block may be made of a fiber-rein and the heat dissipation plate are present in the cooling
forced plastic composite , aluminum , or steel , and may use block .
the fiber -reinforced plastic composite in an embodiment for [ 0049 ] FIG . 5 is an exploded perspective view showing an
realizing a reduction in weight. inner frame and an outer frame in the battery case of FIG .
1.
[ 0033 ] The lower protective plate may be made of a [ 0050 ] FIG . 6 is aa sectional view showing a state in which
material having high impact resistance , and may use the an inner frame, a heat dissipation plate, and an outer frame
fiber - reinforced plastic composite in an embodiment for are coupled to a portion near to a sidewall of the cooling
realizing a reduction in weight.
[ 0034 ] The cooling block may further include a fastening block in the battery case for a vehicle in accordance with an
hole to be fastened to the inner frame through a fastening embodiment of the present disclosure.
hole formed in the heat dissipation plate. [ 0051 ] FIG . 7 is aa sectional view showing a state in which
[ 0035 ] The cooling block may further include a spacer the heat dissipation plate and the outer frame are coupled to
formed around the fastening hole to protrude upwards . an edge portion of the cooling block .
[ 0036 ] The lower protective plate may include a protrud [ 0052 ] FIG . 8 is a sectional view showing a state in which
the heat dissipation plate is coupled to the cooling block in
ing support part formed at a position corresponding to the which the cooling path is formed .
spacer of the cooling block to protrude. [ 0053 ] FIG . 9(a ) is a sectional view showing a state in
[ 0037 ] The lower protective plate may include a fastening which first and third inner frames in an inner frame are
hole formed at a position corresponding to the fastening hole coupled to the cooling block along with the heat dissipation
of each of the cooling block and the heat dissipation plate , plate , and FIG . 9 (6 ) is a sectional view showing a state in
so that the lower protective plate may be fastened to the which a first inner frame of another shape is coupled to the
cooling block and the heat dissipation plate by a fastening cooling block .
member. [ 0054 ] FIG . 10 is an exploded perspective view showing
Advantageous Effects the coupling structure of the heat dissipation plate , the
cooling block , and the lower protective plate of FIG . 2 .
[ 0038 ] A battery case for an electric car according to the [ 0055 ] FIG . 11 illustrates a modification of the cooling
present disclosure can reduce an overall weight while sat block , in which the lower protective plate and the cooling
isfying mechanical performance. block of FIG . 10 are integrally formed .
[ 0039 ] Furthermore , when a battery module is mounted , [ 0056 ] FIG . 12 illustrates another modification of the
water- tightness between an interior and an exterior of a cooling block inserted into the lower protective plate .
battery case is very excellent. [ 0057] FIG . 13 is a sectional view schematically showing
[ 0040 ] Furthermore , a cooling path is formed , so that a the battery case in accordance with an embodiment of the
weight can be reduced while heat conductivity is secured . present disclosure .
[ 0041 ] Furthermore, productivity be enhanced [ 0058 ] FIG . 14 is aa schematically exploded sectional view
through a convenient coupling structure between respective of the battery case shown in FIG . 13 .
components. [ 0059 ] FIG . 15 is a sectional view schematically showing
[ 0042 ] Furthermore, durability is secured through a robust the battery case in accordance with an embodiment of the
assembly structure , and the stability of the battery module present disclosure.
can be maintained even if external force is applied due to a [ 0060 ] FIG . 16 is aa schematically exploded sectional view
multilayered structure . of the battery case shown in FIG . 15 .
[ 0043 ] Furthermore, a battery case can be safely and [ 0061 ] FIG . 17 is aa sectional view schematically showing
firmly protected, and it is easy to replace some components the battery case in accordance with an embodiment of the
when the battery case is damaged . present disclosure.
[ 0044 ] Moreover, a support layer of a battery case is [ 0062 ] FIG . 18 is aa sectional view schematically showing
formed by integrally injection molding two types of fiber the battery case in accordance with an embodiment of the
reinforced plastic composites, and a fastening member is present disclosure.
subjected to injection molding together with the support [ 0063 ] FIG . 19 is a schematically exploded sectional view
layer to couple the fastening member to the support layer, so of the battery case shown in FIG . 18 .
that robustness and productivity can be enhanced . [ 0064 ] FIG . 20 is a sectional view schematically showing
the battery case in accordance with an embodiment of the
BRIEF DESCRIPTION OF THE DRAWINGS present disclosure.
[ 0065 ] FIG . 21 is aa sectional view schematically showing
[ 0045 ] FIG . 1 is a perspective view showing a battery case the battery case in accordance with an embodiment of the
in accordance with an embodiment of the present disclosure . present disclosure.
[ 0046 ] FIG . 2 is an exploded perspective view of the [ 0066 ] FIG . 22 is a sectional view schematically showing
battery case shown in FIG . 1 , in which neither a cooling path the battery case in accordance with an embodiment of the
nor a heat dissipation plate is present in a cooling block . present disclosure.
US 2021/0351455 A1 Nov. 11 , 2021
3

[ 0067] FIG . 23 is aa sectional view schematically showing [ 0089 ] FIG . 45 is a schematic sectional view taken along
the battery case in accordance with an embodiment of the line E - E of an outer frame in the battery case for the vehicle
present disclosure. shown in FIG . 44 .
[ 0068 ] FIG . 24 is a sectional view schematically showing [ 0090 ) FIG . 46 is a configuration diagram schematically
the battery case in accordance with an embodiment of the showing a battery case for a vehicle in accordance with an
present disclosure. embodiment of the present disclosure .
[ 0069 ] FIG . 25 is a diagram schematically showing a state [ 0091 ] FIG . 47 is a configuration diagram schematically
in which a battery module for an electric car is coupled to the showing the technical idea of a battery case package for a
battery case shown in FIG . 13 . vehicle in accordance with the present disclosure .
[ 0070 ] FIG . 26 is a diagram schematically showing a state [ 0092 ] FIG . 48 is a configuration diagram schematically
in which the battery module for the electric car is coupled to showing a lower case and a lower protective plate , in the
the battery case shown in FIG . 18 . battery case package for the vehicle in accordance with an
[ 0071 ] FIG . 27 is aa sectional view schematically showing embodiment of the present disclosure .
the battery case in accordance with an embodiment of the [ 0093 ] FIG . 49 is a schematic sectional view taken along
present disclosure . line F - F of the lower protective plate shown in FIG . 48 .
[ 0072 ] FIG . 28 is aa sectional view schematically showing [ 0094 ] FIG . 50 is a sectional view schematically showing
the battery case in accordance with an embodiment of the an embodiment in which the lower case and the lower
present disclosure. protective plate shown in FIG . 48 are coupled to each other.
[ 0073 ] FIG . 29 is a schematic bottom view of the battery [ 0095 ] FIG . 51 is a configuration diagram schematically
case shown in FIG . 28 . showing a lower protective plate in accordance with an
[ 0074 ] FIG . 30 is a process diagram schematically show embodiment of the present disclosure .
ing a method of manufacturing a battery case in accordance [ 0096 ] FIGS . 52 and 53 are exploded perspective views
with an embodiment of the present disclosure . showing a fiber - reinforced plastic composite including a
[ 0075 ] FIG . 31 is a diagram schematically showing a lamination sheet .
manufacturing step of a manufacturing process shown in [ 0097] FIG . 54 is an exploded perspective view showing
FIG . 30 . a fiber -reinforced plastic composite including a plurality of
[ 0076 ] FIG . 32 is a sectional view schematically showing sheets having different fabric orientation angles .
a battery -case manufacturing process shown in FIG . 30 . [ 0098 ] FIG . 55 is an exploded perspective view of a
[ 0077] FIG . 33 is aa bottom view schematically showing battery case according to the related art.
another embodiment of a lower mold shown in FIG . 31 .
[ 0078 ] FIG . 34 is a configuration diagram schematically DESCRIPTION OF EXEMPLARY
showing a battery case for aa vehicle in accordance with an EMBODIMENTS
embodiment of the present disclosure .
[ 0079 ] FIG . 35 is a sectional view showing a coupling [ 0099 ] Since the present disclosure may be embodied in
portion between an inner frame and a cooling block of the many different forms and have various embodiments, a
battery case for the vehicle shown in FIG . 34 . particular embodiment will be illustrated and described
[ 0080 ] FIG . 36 is aa schematic sectional view taken along herein . However, it is to be understood that the present
line A -A of a first inner frame of the battery case for the description is not intended to limit the present disclosure to
vehicle shown in FIG . 34 . those exemplary embodiments , and the present disclosure is
[ 0081 ] FIG . 37 is a schematic sectional view taken along intended to cover not only the exemplary embodiments, but
line B - B of a second inner frame of the battery case for the also various alternatives, modifications, equivalents and
vehicle shown in FIG . 34 . other embodiments that fall within the spirit and scope of the
present disclosure.
[ 0082 ] FIG . 38 is a schematic sectional view of the first [ 0100 ] The terminology used herein is for the purpose of
inner frame of the battery case for the vehicle in accordance describing particular embodiments only and is not intended
with an embodiment of the present disclosure . to be limiting . In the present disclosure, the singular forms
[ 0083 ] FIG . 39 is a schematic sectional view of the first are intended to include the plural forms as well , unless the
inner frame of the battery case for the vehicle in accordance context clearly indicates otherwise . It will be further under
with an embodiment of the present disclosure. stood that the terms “ comprise ” , “ include ” , “ have” , etc.
[ 0084 ] FIG . 40 is a configuration diagram schematically when used in this specification, specify the presence of
showing a battery case for aa vehicle in accordance with an stated features, integers, steps , operations, elements, com
embodiment of the present disclosure . ponents, and / or combinations of them but do not preclude
[ 0085 ] FIG . 41 is a schematic sectional view taken along the presence or addition of one or more other features,
line C - C of a first inner frame of the battery case for the integers, steps , operations, elements, components, and / or
vehicle shown in FIG . 40 . combinations thereof.
[ 0086 ] FIG . 42 is a configuration diagram schematically [ 0101 ] Hereinafter, the present disclosure will be
showing a battery case for a vehicle in accordance with an explained in detail by describing exemplary embodiments of
embodiment of the present disclosure . the present disclosure with reference to the accompanying
[ 0087] FIG . 43 is aa schematic sectional view taken along drawings . The same reference numerals are used throughout
line D - D of an inner frame of the battery case for the vehicle the drawings to designate the same or similar components.
shown in FIG . 42 . A detailed description of the known function and configu
[ 0088 ] FIG . 44 is a configuration diagram schematically ration which may make the gist of the present disclosure
showing a battery case for a vehicle in accordance with an obscure will be omitted . Likewise , some components may
embodiment of the present disclosure . be exaggerated, omitted or schematically illustrated .
US 2021/0351455 A1 Nov. 11 , 2021
4

[ 0102 ] Hereinafter, a battery case in accordance with an [ 0112 ] The inner frame 100 is coupled to the top surface
embodiment of the present disclosure will be described with of the heat dissipation plate 200 to partition the seat part of
reference to FIGS . 1 to 9 . the battery module .
[ 0103 ] FIG . 1 is a perspective view showing a battery case [ 0113 ] The support part 30 is coupled to the bottom of the
in accordance with an embodiment of the present disclosure , heat dissipation plate 200 , and includes the sidewall 360
FIG . 2 is an exploded perspective view of the battery case extending upwards from the edge portion .
shown in FIG . 1 , in which neither a cooling path nor a heat [ 0114 ] The outer frame 400 is coupled to the outer surface
dissipation plate is present in a cooling block , FIG . 3 is an of the support part 30 .
exploded perspective view of the battery case shown in FIG . [ 0115 ] The sidewall 360 of the support part 30 may be
1 , in which the cooling path is not present and the heat formed at a predetermined height to enclose the heat dissi
dissipation plate is present in the cooling block , and FIG . 4 pation plate 200 and the inner frame 100 as well as the
is an exploded perspective view of the battery case shown in battery module ( not shown ). The heat dissipation plate 200
FIG . 1 , in which both the cooling path and the heat dissi may be coupled to the bottom of the support part 30 inside
pation plate are present in the cooling block . FIG . 5 is an the sidewall 360 , the inner frame 100 may be coupled to the
exploded perspective view showing an inner frame and an top surface of the heat dissipation plate 200 inside the
outer frame in the battery case of FIG . 1. FIG . 6 is a sectional sidewall 360 , and the outer frame 400 may be coupled to the
view showing a state in which an inner frame, a heat lower portion of the outer surface of the sidewall 360 .
dissipation plate, and an outer frame are coupled to a portion [ 0116 ] As shown in FIG . 4 , the battery case 10 may
near to a sidewall of the cooling block in the battery case for include the inner frame 100 , the heat dissipation plate 200,
a vehicle in accordance with an embodiment of the present the cooling block 300 , and the outer frame 400. In the
disclosure , and FIG . 7 is aa sectional view showing a state in embodiment shown in FIG . 4 , an uneven cooling path 310
which the heat dissipation plate and the outer frame are is formed on the top surface of the support part 30 of FIGS .
coupled to an edge portion of the cooling block . FIG . 8 is aa 2 and 3 , thus forming the cooling block 300 .
sectional view showing a state in which the heat dissipation [ 0117 ] First , the battery module ( not shown) is seated and
plate is coupled to the cooling block in which the cooling supported on the top surface of the heat dissipation plate
path is formed , FIG . 9 (a ) is aa sectional view showing a state 200. The heat dissipation plate 200 has generally the shape
in which first and third inner frames in an inner frame are
coupled to the cooling block along with the heat dissipation of a rectangular plate , and is made of metal to secure heat
plate , and FIG . 9 ( b) is a sectional view showing a state in transfer performance . In particular, the heat dissipation plate
which aa first inner frame of another shape is coupled to the 200 is preferably made of aluminum that is metal which is
cooling block . excellent in heat conductivity and is light in weight.
[ 0104 ] Referring to FIGS . 1 to 5 , a battery case 10 in [ 0118 ] The inner frame 100 is coupled to the top surface
accordance with an embodiment of the present disclosure of the heat dissipation plate 200 to partition the seat part of
functions to support a battery module ( not shown) , protect the battery module. In the drawing, the inner frame 100 is
the battery module from external shock , and simultaneously formed to allow eight battery modules to be mounted
cool the battery module . The battery case 10 of the present thereon . That is , the inner frame may be formed to allow two
disclosure supports the battery module from below to form or more battery modules to be mounted thereon .
a lower case , and may be coupled to a cover case which [ 0119 ] To be more specific, the inner frame 100 may be
covers the battery module . composed of first inner frames 110 disposed inside the inner
[ 0105 ] As shown in FIG . 2 , the battery case 10 may frame to extend in a left -and - right direction, second inner
include an inner frame 100 , a support part 30 , and an outer frames 120 disposed on front and rear portions outside the
frame 400 . inner frame to extend in the left-and - right direction, third
[ 0106 ] The support part 30 causes the battery module to be inner frames 130 disposed inside the inner frame to extend
seated therein to support the battery module, and includes a in a front- and - rear direction , and fourth inner frames 140
sidewall 360 extending upwards from an edge portion. disposed on left and right portions outside the inner frame to
extend in the front- and - rear direction .
[ 0107] The inner frame 100 is coupled to the top surface [ 0120 ] The first inner frame 110 may be formed to be
of the cooling block 300 to partition a seat part of the battery higher than other inner frames , and the remaining inner
module .
[ 0108 ] The outer frame 400 is coupled to an outer surface frames may be formed at the same height. However, the
of the cooling block 300 . heights of the first to fourth inner frames 110 , 120 , 130 and
140 are not limited thereto , and the heights of the first to
[ 0109 ] The sidewall 360 of the cooling block 300 may be fourth inner frames 110 , 120 , 130 and 140 may be equal to
formed at a predetermined height to enclose the inner frame or different from each other. The inner frames may be
100 as well as the battery module (not shown ). The inner separately made of a metal material and then be welded to
frame 100 may be coupled to the top surface of the cooling each other.
block 300 inside the sidewall 360 , and the outer frame 400 [ 0121 ] The cooling block 300 is coupled to the bottom of
may be coupled to a lower portion of the outer surface of the the heat dissipation plate 200 , and the uneven cooling path
sidewall 360 .
[ 0110 ] As shown in FIG . 3 , the battery case 10 may
310 is formed on the top surface of the cooling block . The
cooling path 310 is sealed by the bottom surface of the heat
include the inner frame 100 , a heat dissipation plate 200 , the dissipation plate 200 , and the cooling path 310 is configured
support part 30 , and the outer frame 400 .
.
such that a cooling fluid such as coolant or antifreeze
[ 0111 ] First , the battery module ( not shown) is seated and circulates therethrough . Thus, the cooling block 300 cools
supported on the top surface of the heat dissipation plate heat which is generated from the battery module and is
200 . transferred through the heat dissipation plate 200 .
US 2021/0351455 A1 Nov. 11 , 2021
5

[ 0122 ] The cooling path 310 may be formed such that an of the inner frame 100 and the outer frame 400 coupled to
inlet and an outlet are formed in aa side of the cooling block the cooling block 300 by the adhesive as well as the surface
300 and the cooling fluid flows from the inlet to the outlet of the heat dissipation plate 200 may be ground by sanding.
throughout most of the surface of the cooling block 300. The If the adhesive is applied after an adhesive surface is ground,
cooling path 310 may include a continuous first path parti adhesive strength may be further increased .
tion wall 320 which is formed from the bottom surface of the [ 0131 ] The cooling block 300 may include the sidewall
cooling block 300 in an uneven shape and constitutes the 360 extending upwards from the edge portion thereof. This
sidewall of the cooling path 310 , and a second path partition sidewall 360 may be formed at a predetermined height to
wall 330 which is intermittently formed in the cooling path enclose the heat dissipation plate 200 , the inner frame 100
310 to guide the flow of the cooling fluid . as well as the battery module (not shown ). The heat dissi
[ 0123 ] The outer frame 400 is coupled to the outer surface pation plate 200 may be coupled to the bottom of the cooling
of the cooling block 300 , and left and right sides , a front block 300 inside the sidewall 360 , the inner frame 100 may
portion , and a rear portion thereof may be separately coupled be coupled to the top surface of the heat dissipation plate 200
to the cooling block 300 without being connected to each inside the sidewall 360 , and the outer frame 400 may be
other. That is , the outer frame 400 may include aa first side coupled to the lower portion of the outer surface of the
frame 410 and aa second side frame 420 coupled to long sides sidewall 360. As such , the sidewall 360 is formed on the
of the cooling block 300 , and a rear frame 430 and a front cooling block 300 , so that the heat dissipation plate 200 and
frame 440 coupled to short sides of the cooling block 300 . the inner frame 100 are coupled in the cooling block , and the
2

[ 0124 ] The inner frame 100 and the outer frame 400 may outer frame 400 is coupled to the outer portion of the cooling
be made of a material having high stiffness, such as metal or block , thus enhancing the water -tightness of the battery case
fiber -reinforced plastic composites, particularly, a steel 10 .
material to ensure the structural stiffness of the entire battery [ 0132 ] In the three embodiments of FIGS . 2 to 4 , the inner
case 10 . frame 100 and the outer frame 400 may be disposed to be
[ 0125 ] The cooling block 300 may be made of aa material spaced apart from each other with the sidewall 360 of the
such as fiber - reinforced plastic composites, aluminum or cooling block 300 being interposed therebetween . Thus, in
steel , and be made of a fiber - reinforced plastic (FRP ) the three embodiments, the water - tightness of the battery
composite to achieve lightness. In other words , the cooling case 10 can be improved regardless of the presence and
block 300 and the inner frame 100 may be made of different absence of the heat dissipation plate and the cooling path .
materials, or the cooling block 300 and the outer frame 400 [ 0133 ] The coupling structure of the cooling block 300 ,
may be made of different materials . the inner frame 100 , and the outer frame 400 will be
[ 0126 ] The fiber - reinforced plastic composite includes a described later in detail .
sheet produced by combining matrix resin and reinforced [ 0134 ] Meanwhile , FIG . 55 is an exploded perspective
fiber. For example, the sheet may include matrix resin and view of a battery case according to the related art. The
long fiber as the reinforced fiber, or include matrix resin and conventional battery case includes an inner frame 100 ' and
fabric produced by weaving continuous fiber as the rein an outer frame 400 ' , a heat dissipation plate 200 ' , a cooling
forced fiber. The fiber -reinforced plastic composite may block 300 ' , an insulation pad 800 ' , and a lower protective
include aa lamination sheet produced by laminating a plural plate 500' .
ity of sheets. [ 0135 ] The inner frame 100 ' and the outer frame 400 ' are
[ 0127] In this case , the inner frame 100 and the outer made of metal such as steel or aluminum , and are coupled
frame 400 may be made of a material different from the to each other by welding . The outer frame 400 ' includes a
cooling block 300 made of the fiber - reinforced plastic com sidewall extending upwards from the edge portion thereof.
posite , and be made of a steel material so as to increase the Instead , the sidewall is not formed on the cooling block 300 ' .
mechanical strength of the cooling block 300 made of a The outer frame 400 ' is closed on all sides thereof because
fiber -reinforced plastic composite. front, rear , left and right sidewalls thereof are connected to
[ 0128 ] The inner frame 100 and the outer frame 400 made each other .
of a steel material may be attached to the cooling block 300 [ 0136 ] The heat dissipation plate 200 ' may be made of an
made of a fiber - reinforced plastic composite by an adhesive. aluminum material, as in the present disclosure . However, in
Since the inner frame 100 and the heat dissipation plate 200 the related art, an insulation pad 800 ' is separately provided
are different kinds of metal, i.e. steel and aluminum , the under the cooling block 300 ' to prevent heat from being
inner frame and the heat dissipation plate may be coupled transferred downwards. The lower protective plate 500 ' is
not by welding but by the adhesive . Furthermore, the heat also made of aa metal material.
dissipation plate 200 and the cooling block 300 may also be [ 0137] As such , since all components of the conventional
coupled to each other by the adhesive . battery case are made of metal such as steel or aluminum , it
[ 0129 ] The cooling block 300 may be formed to have the is very disadvantageous in terms of ?a reduction in weight .
thickness of 2 to 5 mm , and the adhesive may be applied [ 0138 ] Thereby, there are attempts to change the material
with the thickness of 0.3 to 1 mm . As the fiber - reinforced into the fiber -reinforced plastic composite for the purpose of
plastic composite of the cooling block 300 is low in heat lightness . Since it is difficult to satisfy structural stiffness
conductivity and is excellent in heat insulation properties, it only by the fiber - reinforced plastic composite , there has
is possible to secure sufficient heat insulation properties been proposed a method where the inner and outer frames
without including a separate insulation member. In this case , are still made of ?a metal material and the weight of parts for
in order to secure the heat insulation properties, the thick supporting the battery on a bottom surface , such as the
ness of the cooling block 300 of 2 to 5 mm may be sufficient. cooling block, is reduced . However, dissimilar bonding
[ 0130 ] The surface of the cooling block 300 to which the between metal and plastic is not reliable , so that water
adhesive is applied may be ground by sanding. The surfaces tightness is not excellent.
US 2021/0351455 A1 Nov. 11 , 2021
6

[ 0139 ] If a plurality of battery modules is seated on the compound ( SMC ) is an intermediate product which is pro
battery case 10 , the top surface of the battery module and the cessed in the form of a sheet without being limited to a
upper end of the sidewall 360 may be disposed at the same specific length and type of fiber, and the fiber -reinforced
height. Thus, the bottom surface of a cover case which plastic composite which may be cured through the hot press
covers the top of the battery module and is coupled to the is defined as the SMC .
battery case 10 may be formed in a flat shape . [ 0148 ] Therefore, in the present disclosure , the SMC may
[ 0140 ] Furthermore , the cooling block 300 may include include reinforced fiber in the form of fabric which is woven
fastening holes 350 to be fastened to the inner frame 100 by continuous fiber, or may be an intermediate product
through fastening holes 250 which are formed in the heat which is made in the form of a sheet using the fiber
dissipation plate 200. To this end , the inner frame 100 may reinforced plastic composite including the continuous fiber
have fastening holes 150 which are formed in the first inner oriented in one direction as the reinforced fiber.
frame 110. Thus , the adhesive may be applied between the [ 0149 ] Furthermore , in the present disclosure , the SMC is
inner frame 100 , the heat dissipation plate 200 , and the not limited by the type of fiber (glass fiber, carbon fiber,
cooling block 300 , and simultaneously they may be coupled aramid fiber, nylon , PP fiber, etc.).
all together by a fastening member. [ 0150 ] The matrix resin combined with the reinforced
[ 0141 ] The cooling block 300 may further include a spacer fiber may be any one selected from a group including
340 which is formed around the fastening hole 350 to thermoplastic resin , curable resin , and a mixture thereof.
protrude upwards. This spacer 340 is formed to enclose the
fastening hole 350 , and the cooling path 310 is not formed [ 0151 ] The fiber - reinforced plastic composite may include
in the spacer 340. The spacer 340 may increase fastening reinforced fiber in the form of long fiber or reinforced fiber
force and strength when a fastening operation is performed in the form of fabric woven by continuous fiber in the matrix
through the fastening hole 350 . resin .
[ 0142 ] Meanwhile , the heat dissipation plate 200 may [ 0152 ] Preferably, the battery case for an electric car
include an unformed part 240 from which a portion corre according to the present disclosure further includes the
sponding to the spacer 340 that is the portion where the lower protective plate 500 which is coupled to the lower
cooling path of the cooling block is not formed is omitted . portion of the cooling block 300 .
The width of the unformed part 240 may be formed to be [ 0153 ] The lower protective plate 500 may have the shape
smaller than that of the spacer 340 , and the length of the of a flat plate corresponding to the bottom surface of the
unformed part 240 may be formed to be equal to or smaller cooling block . Furthermore , the lower protective plate 500
than the length of the spacer 340. By forming the unformed may be made of the fiber - reinforced plastic composite.
part 240 on the heat dissipation plate 200 , it is possible to [ 0154 ] The lower protective plate 500 may include a
save a material and further reduce a weight. protruding support part 540 which is formed at a position
[ 0143 ] By such a configuration, the compressive strength corresponding to the spacer 340 of the cooling block 300 to
of the battery case 10 may range from 150 kN to 250 kN , protrude, and a fastening hole 550 which is formed at a
particularly from 200 kN to 230 kN . The compressive position corresponding to the fastening hole 350 of the
strength of the battery case 10 means the compressive cooling block 300 .
strength on four sides , except for the upper and lower [ 0155 ] The protruding support part 540 may come into
portions of the battery case 10. The compressive
? strength of contact with the bottom surface of the spacer 340 to support
the battery case 10 may be measured by a method where a the cooling block 300 .
compressive plate is placed on an opposite surface and then
a load is applied thereto under the condition that one surface [ 0156 ] The fastening hole 550 of the lower protective plate
is fixed (Chinese GB / T 31467.3 standard ). When the com 500 is formed at a position corresponding to the fastening
pressive strength of the battery case 10 is 150 kN or less hole 350 of the cooling block 300 , so that the lower
before the compressive plate reaches the battery, impact is protective plate 500 , the cooling block 300 , the heat dissi
exerted on the battery in the event of a vehicle collision , so pation plate 200 , and the inner frame 100 may be fastened
that explosion and fire may occur . When the compressive all together by the fastening member.
strength of the battery case 10 exceeds 250 kN , the effect of [ 0157] Meanwhile, the cooling block 300 and the lower
reducing weight may be reduced . protective plate 500 may be integrally formed . The cooling
[ 0144 ] Meanwhile, the cooling block 300 may be made of block 300 and the lower protective plate 500 are formed of
a fiber reinforced plastic (FRP ) composite . the same fiber - reinforced plastic composite. Hence, if they
[ 0145 ] The fiber -reinforced plastic composite (FRP ) are integrally formed , the cooling block 300 may be thicker
includes a sheet by combining matrix resin and reinforced by the thickness of the lower protective plate 500 .
fiber, and is classified into various types depending on a [ 0158 ] The lower protective plate 500 may include a
purpose , a process , required properties, the type, length , sidewall 530 ( see FIG . 12 ) extending upwards from an edge
content, orientation method of fiber, and the type of impreg portion thereof, and a fastening hole 550 to be fastened to the
nating matrix resin . inner frame 100 through the fastening holes 350 and 250
[ 0146 ] As the representative fiber - reinforced plastic com formed in the cooling block 300 and the heat dissipation
posite , there are a sheet molding compound ( SMC ) , a bulk plate 200. The latter two embodiments will be described
molding compound (BMC ) , prepreg , etc. later.
[ 0147 ] Generally, the sheet molding compound ( SMC ) is [ 0159 ] FIG . 6 is aa sectional view showing a state in which
an intermediate product which is processed in the form of a the inner frame, the heat dissipation plate, and the outer
sheet by mixing thermosetting resin and long fiber ( 2 to 50 frame are coupled to a portion near to the sidewall of the
mm ), and refers to fiber reinforced plastic which is cured cooling block in the battery case for the vehicle in accor
through a hot press. However, herein , the sheet molding dance with an embodiment of the present disclosure . FIG . 7
US 2021/0351455 A1 Nov. 11 , 2021
7

is a sectional view showing a state in which the heat an elongated rectangular shape, and a plurality of perfora
dissipation plate and the outer frame are coupled to the edge tions each having the inner diameter of 3 mm was formed in
portion of the cooling block . this adhesive portion.
[ 0160 ] The cooling block 300 may include the sidewall [019] After the perforation was formed and then an
360 extending upwards from the edge portion thereof. This aluminum specimen and a fiber - reinforced plastic composite
sidewall 360 may be formed at a predetermined height to sheet were attached , a tensile test was performed. When
enclose the heat dissipation plate 200 , the inner frame 100 , comparing a case where the perforation was formed with a
and the battery module . case where no perforation was formed , it can be seen that
[ 0161 ] The heat dissipation plate 200 may be coupled to a tensile strength is increased by about 70 % .
stepped part 370 formed on a bottom inside the sidewall 360 [ 0170 ] FIG . 8 is aa sectional view showing a state in which
of the cooling block 300 by the adhesive 600. After the heat the heat dissipation plate is coupled to the cooling block in
dissipation plate 200 is coupled to the stepped part 370 , the which the cooling path is formed , and FIG . 9 ( a ) is a
top surface of the heat dissipation plate 200 and the bottom sectional view showing a state in which the first and third
of the edge portion of the cooling block 300 are preferably inner frames in the inner frame are coupled to the cooling
disposed to form the same plane. block along with the heat dissipation plate , and FIG . 9 ( b) is
[ 0162 ] FIG . 6 is a longitudinal sectional view taken along a sectional view showing a state in which a first inner frame
a plane passing through the center of the first inner frame of another shape is coupled to the cooling block .
110. After the first inner frame 110 and the fourth inner [ 0171 ] As shown in FIG . 8 , a plurality of uneven cooling
frame 140 are coupled to each other by welding, they are paths 310 may be formed on the top surface of the cooling
disposed such that lower ends thereof form the same plane. block 300 , and the plurality of cooling paths 310 may be
[ 0163 ] The inner frame 100 may be coupled to the top partitioned by an intermittent second path partition wall 330 .
surface of the heat dissipation plate 200 and the bottom of In this case , the cooling block 300 may be formed such that
the edge portion of the cooling block 300 inside the sidewall the second path partition wall 330 has a thickness similar to
360 of the cooling block 300 by the adhesive. The first inner those of other portions.
frame 110 may be formed in height to be about aa half of the [ 0172 ] The top surface of the second path partition wall
sidewall 360 . 330 may have a planar area having a predetermined width ,
[ 0164 ] The outer frame 400 may be coupled to the lower
and the heat dissipation plate 200 may be coupled by the
portion of the outer surface of the sidewall 360. The inner adhesive 600 which is applied to the top surface of the
surface of the outer frame 400 may be coupled to the lower second path partition wall 330 .
portion of the outer surface of the sidewall 360 by the [ 0173 ] A planar area having a wider width may be present
adhesive 600 , and the height of the upper end of the coupled in the bottom surface on which the cooling path 310 of the
outer frame 400 may be similar to the height of the first inner cooling block 300 is formed , and the lower protective plate
frame 110 . 500 may come into contact with the bottom surface having
the cooling path 310 to be coupled thereto .
[ 0165 ] A horizontal rib 450 may be formed on the outer [ 0174 ] FIG . 9 ( a ) is a partial sectional view taken along a
frame 400 to extend inwards and support the bottom surface plane which passes through the center of the first inner frame
of the edge portion of the cooling block 300. Thus, the top 110 and the third inner frame 130 and is parallel to the third
surface of the horizontal rib 450 may be coupled to the inner frame 130 , and FIG . 9 (b ) is a sectional view taken
bottom surface of the edge portion of the cooling block 300 along a plane perpendicular to the first inner frame 110 to
by the adhesive 600 . show a state in which the first inner frame of another shape
[ 0166 ] The horizontal rib 450 is vertically disposed under is coupled to the cooling block .
the fourth inner frame 140 with the cooling block 300 being [ 0175 ] As shown in FIG . 9 ( a ) , the cooling path may not be
interposed therebetween , so that the inner frame 100 , the formed in an area of the cooling block 300 where the first
cooling block 300 , and the outer frame 400 may be more inner frame 110 is disposed . That is , the first inner frame 110
firmly coupled to each other. may be directly coupled to the cooling block 300 by the
[ 0167] Meanwhile, as shown in FIG . 7 , a plurality of adhesive 600 in an area where the cooling path is not formed
perforations 376 may be formed in the bottom of the stepped on the top surface of the cooling block 300 .
part 370 to which the heat dissipation plate 200 is attached . [ 0176 ] The stepped part 370 for seating the heat dissipa
The plurality of perforations 376 is holes formed at a tion plate 200 thereon may be formed on the edge of the top
predetermined depth in a surface to which the adhesive 600 surface of the cooling block 300 where the cooling path is
is applied . When the cooling block 300 has the thickness of not formed . Thus, the bottom surface of the third inner frame
2 to 5 mm , the perforation 376 may be formed to have the 130 and the top surface of the heat dissipation plate 200 may
inner diameter of 2 to 3 mm . The perforation 376 may or be coupled by the adhesive 600 , and the bottom surface of
may not pass through the cooling block 300. If the adhesive the heat dissipation plate 200 and the top surface of the
600 is applied, it is introduced into each perforation 376 to cooling block 300 may be coupled by the adhesive 600 .
further increase adhesion . [ 0177] As shown in FIG . 9 (b ) , the cooling block 300
[ 0168 ] In order to check adhesive strength when the includes the spacer 340 formed on a portion, to which the
perforation was formed , an experiment was performed com first inner frame 110 is coupled , to protrude upwards. The
pared to a case where no perforation was formed . A metal cooling path is not formed on the spacer 340. Stepped parts
specimen was made of aluminum 60 series, and an adhesive 370 may be formed on both ends of the spacer 340 so that
was applied at the thickness of 0.3 mm to a surface of the the heat dissipation plate 200 is seated and coupled by the
fiber - reinforced plastic composite sheet including glass fiber adhesive 600 .
in the form of long fiber in ultrahigh molecular weight [ 0178 ] The section of the first inner frame 110 may have
polyethylene (UPE ) matrix resin . An adhesive portion had the shape of aa hollow closed curved surface. To be more
US 2021/0351455 A1 Nov. 11 , 2021
8

specific , the section of the first inner frame 110 may have the a fiber - reinforced plastic composite. For example, the cool
shape of a rectangular closed curved surface. Thus, the ing block may be made of a fiber - reinforced plastic com
bottom surface of the first inner frame 110 and the spacer posite including long fiber, and the lower protective plate
340 of the cooling block 300 may be coupled by the may be made of a fiber - reinforced plastic composite includ
adhesive 600 . ing woven fiber, so that they may be integrally formed .
[ 0179 ] Furthermore, the first inner frame 110 and the [ 0189 ] In the case of the coupling structure of the cooling
spacer 340 of the cooling block 300 may be coupled by a block shown in FIG . 12 , the heat dissipation plate 200 is the
fastening member 700. To this end, the fastening hole 150 same as the heat dissipation plate of FIG . 10 but includes a
may be formed in the upper and bottom surfaces of the first cooling block 306 having no sidewall and aa lower protective
inner frame 110 , and the fastening hole 350 may be formed plate 503 having a sidewall 530 .
in the spacer 340 of the cooling block 300. The fastening [ 0190 ] The heat dissipation plate 200 is made of an
member 700 may be composed of a bolt 710 and a nut 720 aluminum material. The cooling block 306 may be made of
which pass through the fastening holes 150 and 350 to be a fiber - reinforced plastic composite, and be made of an
fastened thereto . aluminum material. If the cooling block 306 is made of the
[ 0180 ] Next , three embodiments for the coupling structure fiber -reinforced plastic composite, it may be coupled to the
of the heat dissipation plate , the cooling block , and the lower heat dissipation plate 200 by an adhesive . If the cooling
protective plate in the battery case of the present disclosure block 306 is made of an aluminum material, it may be
will be described with reference to FIGS . 10 to 12 . coupled to the heat dissipation plate 200 by welding. As this
[ 0181 ] FIG . 10 is an exploded perspective view showing welding method, friction stir welding may be used .
the coupling structure of the heat dissipation plate , the [ 0191 ] The lower protective plate 503 is made of a fiber
cooling block, and the lower protective plate of FIG . 4 , FIG . reinforced plastic composite, and integrally includes aa side
11 illustrates a modification of the cooling block , in which wall 530 extending upwards from an edge portion thereof.
the lower protective plate and the cooling block of FIG . 10 Since the sidewall 530 is integrally formed on the lower
are integrally formed , and FIG . 12 illustrates another modi protective plate 503 , water - tightness may be improved and
fication of the cooling block inserted into the lower protec the number of assembly processes may be reduced .
tive plate. [ 0192 ] Hereinafter, various lamination structures of the
[ 0182 ] In the case of the coupling structure of the cooling inner frame 100 , the heat dissipation plate 200 , the cooling
block 300 shown in FIG . 10 , the heat dissipation plate 200 ,
2 block 300 , the outer frame 400 , and the lower protective
the cooling block 300 , and the lower protective plate 500 are plate 500 constituting the battery case of the present disclo
included . sure will be described with reference to FIGS . 13 to 26 .
[ 0183 ] The heat dissipation plate 200 is made of an [ 0193 ] FIG . 13 is a sectional view schematically showing
aluminum material. The cooling block 300 is made of a the battery case in accordance with an embodiment of the
fiber - reinforced plastic composite, and integrally includes present disclosure , and FIG . 14 is a schematically exploded
the sidewall 360 extending upwards from the edge aportion sectional view of the battery case shown in FIG . 13 .
thereof. The lower protective plate 500 is made of a fiber [ 0194 ] The battery case 10 functions to support a battery
reinforced plastic composite , and has the shape of a flat plate module, protect the battery module from external shock , and
corresponding to that of the bottom surface of the cooling simultaneously cool the battery module.
block 300 . [ 0195 ] As shown in the drawing, the battery case 10
[ 0184 ] The heat dissipation plate 200 , the cooling block includes the heat dissipation plate 200 , the cooling block
300 , and the lower protective plate 500 may be coupled to 300 , an adhesive layer 600 , and the lower protective plate
each other by the adhesive . In addition , they may have 500 .
fastening holes to be coupled all together. The heat dissipa [ 0196 ] To be more specific , the battery module ( not
tion plate 200 and the cooling block 300 may be first coupled shown) is coupled to one surface of the heat dissipation plate
to each other , and then the inner frame 100 and the outer 200 , while the cooling block 300 is coupled to the other
frame 400 may be coupled to each other . Finally , the lower surface of the heat dissipation plate 200. In order to couple
protective plate 500 may be coupled thereto . the heat dissipation plate 200 and the cooling block 300 , the
[ 0185 ] Since the sidewall 360 is formed integrally on the adhesive layer 600 is coupled to the other surface of the heat
cooling block 300 , the cooling path of the cooling block 300 dissipation plate 200 .
may have water -tightness so that there is no water leakage [ 0197] Furthermore, the heat dissipation plate 200 is made
at 12 bar. of metal to secure thermal conductivity. Furthermore, the
[ 0186 ] In the case of the coupling structure of the cooling heat dissipation plate 200 may be made of aluminum to
block shown in FIG . 11 , the heat dissipation plate 200 is the realize lightness.
same as the heat dissipation plate 200 of FIG . 10 but [ 0198 ] The cooling block 300 includes a plurality of
includes a cooling block 305 integrated with the lower uneven cooling paths 310 formed to be opened to the top
protective plate . surface.
[ 0187] The cooling block 305 is integrated with the lower [ 0199 ] The lower protective plate 500 may be coupled to
protective plate, and the thickness of the cooling block 305 the bottom surface of the cooling block 300. The cooling
may be equal to or larger than the cooling block 300 of FIG . block 300 and the lower protective plate 500 may be made
10 which is manufactured separately from the lower pro of two different kinds of fiber -reinforced plastic composites,
tective plate 500 and then coupled thereto . The cooling and be integrally formed through injection molding.
block 305 includes aa sidewall 360 extending upwards from [ 0200 ] As an example, the cooling block 300 may be made
an edge portion thereof. of a fiber - reinforced plastic composite including matrix resin
[ 0188 ] In the integral cooling block 305 , the cooling block and long fiber as reinforced fiber, the lower protective plate
and the lower protective plate may be integrally formed of 500 may be made of aa fiber - reinforced plastic composite
US 2021/0351455 A1 Nov. 11 , 2021
9

including matrix resin and fabric woven with continuous [ 0212 ] The battery case of this embodiment further
fiber as reinforced fiber, and the fiber - reinforced plastic includes a fastening member 700 compared to the battery
composite including reinforced fiber in the form of long case shown in FIG . 13 .
fiber and the fiber -reinforced plastic composite including [ 0213 ] As shown in the drawing, the battery case 10
reinforced fiber in the form of fabric may be integrally includes the heat dissipation plate 200 , the cooling block
formed through injection molding, thus forming the cooling 300 , the adhesive layer 600 , the lower protective plate 500,
block 300 . and the fastening member 700 .
[ 0201 ] The adhesive layer 600 is coupled to one surface of [ 0214 ] Furthermore, the heat dissipation plate 200 , the
the cooling block 300 , while the lower protective plate 500 cooling block 300 , the adhesive layer 600 , and the lower
is coupled to the other surface of the cooling block 300. The protective plate 500 are the same as the heat dissipation plate
cooling path 310 is formed on the cooling block 300. Fluid 200 , the cooling block 300 , the adhesive layer 600 , and the
for cooling the battery module (not shown) circulates in the lower protective plate 500 shown in FIG . 13 , and only a
cooling path 310 . coupling structure coupled with the fastening member 700 is
[ 0202 ] The cooling path 310 may be opened to a top included .
surface TS which is one surface of the cooling block 300 to [ 0215 ] To be more specific, the fastening member 700 of
which the adhesive layer 600 is coupled, and may have the the battery case as well as the adhesive layer 600 functions
shape of a groove which is curved to a bottom surface BS to couple the heat dissipation plate 200 and the cooling block
which is the other surface of the cooling block 300 . 300. To this end, the fastening member 700 may be imple
[ 0203 ] The cooling path 310 extends not in a laminating mented in various forms, such as a rivet, a bolt /nut, or a
direction Z but in a direction parallel to a side forming a fastening bolt , to physically couple a plurality of compo
lamination surface . FIG . 14 illustrates an embodiment where nents . FIG . 15 illustrates an example where the fastening
the cooling path extends in aa Y - axis direction which is one member 700 is composed of a set of a bolt and a nut.
axis direction of the lamination surface of the cooling block [ 0216 ] That is , the fastening member 700 includes aa bolt
300 . 710 and a nut 720 .
[ 0204 ] Furthermore, a plurality of cooling paths 310 may [ 0217] Furthermore, in order to couple the heat dissipation
be formed to be spaced apart from each other in an X - axis plate 200 and the cooling block 300 using the fastening
direction which is another axis direction of the lamination member 700 , the fastening hole 250 through which the bolt
surface. For example, FIG . 14 illustrates that the adjacent 710 passes is formed in the heat dissipation plate 200 .
first cooling path 311 and second cooling path 312 are Furthermore, the nut 720 is coupled to the cooling block
formed . 300 .
[ 0205 ] Next , the lower protective plate 500 functions to [ 0218 ] Furthermore , the nut 720 is coupled to the cooling
support the load of the battery module , and secure the block 300 , and is located between the cooling paths.
robustness of the cooling block 300. The lower protective [ 0219 ] That is , the nut 720 is located between neighboring
plate 500 is coupled to the bottom surface BS of the cooling first and second cooling paths 311 and 312 .
block 300 . [ 0220 ] As described above, the cooling block 300 is made
[ 0206 ] Furthermore , the lower protective plate 500 pro of aa fiber -reinforced plastic composite including reinforced
tects the battery module from external shock . fiber in the form of long fiber, the lower protective plate 500
[ 0207] As described above , the adhesive layer 600 func is made of a fiber -reinforced plastic composite including
tions to physically couple the heat dissipation plate 200 and reinforced fiber in the form of fabric , and the nut 720 , the
the cooling block 300 , and is interposed between the heat fiber - reinforced plastic composite including reinforced fiber
dissipation plate 200 and the cooling block 300 . in the form of long fiber and the fiber- reinforced plastic
composite including reinforced fiber in the form of fabric
[ 0208 ] Furthermore, a width D2 of the adhesive layer 600 may be integrally formed through injection molding , thus
may be formed to be equal or similar to a width D1 of the forming the cooling block 300 .
top surface TS of the cooling block 300 on which the cooling [ 0221 ] In a state where the cooling block is made in this
path is not formed . way and the heat dissipation plate 200 is coupled to the
[ 0209 ] Furthermore, the adhesive layer 600 is coupled to cooling block 300 by the adhesive layer 600 , the bolt 710
2

the top surface TS of the cooling block 300 , and is located passes through the fastening hole 250 of the heat dissipation
in an area between adjacent cooling paths. That is , the plate 200 and is fastened to the nut 720 coupled to the
adhesive layer 600 is located on the top surface TS of the cooling block 300 .
cooling block 300 between the first cooling path 311 and the [ 0222 ] In this case , a head 712 of the bolt 710 is fastened
second cooling path 312 which are adjacent to each other. to the nut 720 while pressing the top surface of the heat
Thus, the leakage of fluid circulating along the first cooling dissipation plate 200 .
path 311 and the second cooling path 312 is prevented by the [ 0223 ] Thus , as the battery case according to an embodi
adhesive layer 600 , so that the water - tightness of the battery ment of the present disclosure couples the heat dissipation
case is improved plate 200 and the cooling block 300 by the fastening member
[ 0210 ] The cooling block 300 of the battery case accord 700 as well as the adhesive layer 600 , they may be more
ing to an embodiment of the present disclosure may be made firmly coupled to each other and durability may be secured
of aa fiber reinforced composite material. against external shock.
[ 0211 ] FIG . 15 is aa sectional view schematically showing [ 0224 ] Furthermore , as the fastening member is used , a
the battery case in accordance with an embodiment of the relative movement between the heat dissipation plate 200
present disclosure , and FIG . 16 is a schematically exploded and the cooling block 300 is prevented due to the curing of
sectional view of the battery case shown in FIG . 22 . the adhesive layer, thus facilitating precise coupling.
US 2021/0351455 A1 Nov. 11 , 2021
10

[ 0225 ] Furthermore , the nut 720 may be integrated with [0240] A seat groove 152 in which the head 712 of the bolt
the cooling block 300 through injection molding. 710 is seated may be formed on the inner frame 100. The
[ 0226 ] FIG . 17 is a sectional view schematically showing depth of the seat groove 152 is formed to be equal to or
the battery case in accordance with an embodiment of the larger than the height of the head 712 of the bolt 710 .
present disclosure . [ 0241 ] Thus, when the bolt 710 is coupled to the inner
[ 0227] To be more specific, the battery case further frame 100 , the head 712 of the bolt 710 is inserted into the
includes an adhesive layer and an inner frame compared to seat groove 152 , and the fastening member 700 does not
the battery case shown in FIG . 13 . protrude outwards from the inner frame 100. Thereby, when
[ 0228 ] As shown in the drawing , the battery case includes the battery module BM is coupled to the inner frame 100
the inner frame 100 , a first adhesive layer 610 , the heat
2 ( see FIG . 26 ) , interference by the fastening member 700
dissipation plate 200 , a second adhesive layer 620 , the does not occur, and the coupling force of the fastening
cooling block 300 , and the lower protective plate 500 . member 700 is also increased .
[ 0229 ] Furthermore , the heat dissipation plate 200 , the
2 [ 0242 ] Furthermore, the nut 720 is coupled to the cooling
cooling block 300 , and the second adhesive layer 620 are the block 300. Furthermore, the nut 720 is located between the
same as the heat dissipation plate 200 , the cooling block 300 , cooling paths 310 in the cooling block 300 .
and the adhesive layer 600 shown in FIG . 13 . [ 0243 ] FIG. 20 is sectional view schematically showing
[ 0230 ] The cooling path 310 in which fluid circulates to the battery case in accordance with an embodiment of the
cool the battery module (not shown ) is formed on the present disclosure.
cooling block 300 . [ 0244 ] The battery case remains the same as the battery
[ 0231 ] The inner frame 100 functions to more firmly case shown in FIG . 13 except for only the shape of the
secure the battery module ( not shown) and reinforce the adhesive layer.
stiffness of the battery case . To this end, the inner frame 100 [ 0245 ] As shown in the drawing, the battery case includes
is coupled to the heat dissipation plate 200 by the first the heat dissipation plate 200 , the cooling block 300 , the
adhesive layer 610. That is , the first adhesive layer 610 is adhesive layer 600 , and the lower protective plate 500 .
interposed between the heat dissipation plate 200 and the [ 0246 ] Furthermore , the heat dissipation plate 200 and the
inner frame 100 . cooling block 300 are the same as the heat dissipation plate
[ 0232 ] The battery case according to an embodiment of 200 and the cooling block 300 shown in FIG . 13. The
the present disclosure, which is configured as described adhesive layer 600 has a shape corresponding to that of the
above , may more firmly secure the battery module by the heat dissipation plate 200 , and is coupled to the cooling
inner frame, reinforce the stiffness of the battery case , block 300 while covering the cooling path 310 .
simplify a coupling process and enhance productivity as the [ 0247] As described above , as the adhesive layer 600 is
inner frame is coupled and secured to the heat dissipation composed of one sheet, the adhesive layer 600 may be
plate by the first adhesive layer. conveniently coupled to the heat dissipation plate 200 and
[ 0233 ] FIG . 18 is aa sectional view schematically showing the cooling block 300 , and productivity may be enhanced .
the battery case in accordance with an embodiment of the [ 0248 ] FIG . 21 is a sectional view schematically showing
present disclosure, and FIG . 19 is aa schematically exploded the battery case in accordance with an embodiment of the
sectional view of the battery case shown in FIG . 18 . present disclosure.
[ 0234 ] To be more specific, the battery case further [ 0249 ] The battery case remains the same as the battery
includes a fastening member compared to the battery case case shown in FIG . 20 except for only the shape of a
shown in FIG . 17 .
[ 0235 ] As shown in the drawing, the battery case includes cooling -path formation layer.
the inner frame 100 , the first adhesive layer 610 , the heat
9
[ 0250 ] As shown in the drawing, the battery case includes
dissipation plate 200 , the second adhesive layer 620 , the the heat dissipation plate 200 , the cooling block 300 , the
cooling block 300 , the lower protective plate 500 , and a adhesive layer 600 , and the lower protective plate 500 .
fastening member 700 . [ 0251 ] Furthermore, the heat dissipation plate 200 and the
[ 0236 ] Furthermore, the heat dissipation plate 200 , the adhesive layer 600 are the same as the heat dissipation plate
cooling block 300 , the second adhesive layer 620 , and the 200 and the adhesive layer 600 shown in FIG . 20 .
first adhesive layer 610 are the same as the heat dissipation [ 0252 ] The cooling path 310 through which fluid for
plate 200 , the cooling block 300 , the second adhesive layer cooling the battery module circulates is formed on the
620 , and the first adhesive layer 610 shown in FIG . 17 , and cooling block 300. The cooling block 300 may be formed
only a coupling structure coupled with the fastening member such that the top surface thereof is opened to correspond to
700 is included . the cooling path 310 and the bottom surface between adja
[ 0237] The fastening member 700 as well as the second cent cooling paths 310 is opened .
adhesive layer 620 and the first adhesive layer 610 couples [ 0253 ] As described above, the battery case is reduced in
the heat dissipation plate 200 , the cooling block 300 , and the material cost , and is improved in productivity.
inner frame 100 . [ 0254 ] FIG . 22 is a sectional view schematically showing
[ 0238 ] To this end, the fastening member 700 includes the the battery case in accordance with an embodiment of the
bolt 710 and the nut 720 . present disclosure .
[ 0239 ] Furthermore, in order to couple the inner frame [ 0255 ] The battery case remains the same as the battery
100 , the heat dissipation plate 200 , and the cooling block case shown in FIG . 21 except for only the shape of the
300 using the fastening member 700 , the fastening hole 150 adhesive layer.
through which the bolt 710 passes is formed in the inner [ 0256 ] As shown in the drawing, the battery case includes
frame 100 , and the fastening hole 250 through which the bolt the heat dissipation plate 200 , the cooling block 300 , the
710 passes is formed in the heat dissipation plate 200 . adhesive layer 600 , and the lower protective plate 500 .
US 2021/0351455 A1 Nov. 11 , 2021
11

[ 0257] Furthermore , the heat dissipation plate 200 and the [ 0272 ] That is , the cooling block 300 is made of a fiber
cooling block 300 are the same as the heat dissipation plate reinforced plastic composite including reinforced fiber in the
200 and the cooling block 300 shown in FIG . 21. The form of long fiber, the lower protective plate 500 is made of
adhesive layer 600 has a shape corresponding to that of the a fiber - reinforced plastic composite including reinforced
heat dissipation plate 200 , and is coupled to the cooling fiber in the form of fabric, and the nut 720 , the fiber
block 300 while covering the cooling path 310 . reinforced plastic composite including reinforced fiber in the
[ 0258 ] As described above , as the adhesive layer 600 is form of long fiber and the fiber - reinforced plastic composite
composed of one sheet, the adhesive layer 600 may be including reinforced fiber in the form of fabric may be
conveniently coupled to the heat dissipation plate 200 and integrally formed through injection molding , thus forming
the cooling block 300a , and productivity may be enhanced . the cooling block 300 .
[ 0259 ] FIG . 23 is a sectional view schematically showing [ 0273 ] The seat groove 152 in which the head 712 of the
the battery case in accordance with an embodiment of the bolt 710 is seated may be formed on the inner frame 100 .
present disclosure . The depth of the seat groove 152 is formed to be equal to or
[ 0260 ] As shown in the drawing , the battery case includes larger than the height of the head of the bolt 710 .
the inner frame 100 , the cooling block 300 , the adhesive [ 0274 ] FIG . 25 is a diagram schematically showing a state
layer 600 , and the lower protective plate 500 . in which the battery module for the electric car is coupled to
[ 0261 ] To be more specific, the battery module (not the battery case shown in FIG . 13 .
shown) is coupled to one surface of the inner frame 100 , and [ 0275 ] As shown in the drawing, the battery module BM
the cooling block 300 is coupled to the other surface of the for the electric car is coupled to the top of the battery case .
inner frame 100. In order to couple the cooling block 300 [ 0276 ] To be more specific , the battery case is the same as
and the inner frame 100 , the adhesive layer 600 is coupled the battery case shown in FIG . 13. That is , the battery case
to the other surface of the inner frame 100 . includes the heat dissipation plate 200 , the cooling block
[ 0262 ] That is , the adhesive layer 600 is interposed 300 , the adhesive layer 600 , and the lower protective plate
between the cooling block 300 and the inner frame 100 . 500 .
[ 0263 ] The cooling block 300 and the lower protective [ 0277] Furthermore , the battery module BM for the elec
plate 500 may be made of two different kinds of fiber tric car is coupled to the top surface of the heat dissipation
reinforced plastic composites , and be integrally formed plate 200. Thus, the battery case supports the battery module
through injection molding. BM for the electric car, and simultaneously protects the
[ 0264 ] Furthermore, the cooling block 300 is made of a battery module BM for the electric car from external force .
fiber - reinforced plastic composite including reinforced fiber [ 0278 ] Furthermore, heat generated from the battery mod
in the form of long fiber , the lower protective plate 500 is ule BM for the electric car is transferred through the heat
made of a fiber - reinforced plastic composite including rein dissipation plate 200 , and cooled through the cooling path
forced fiber in the form of fabric , and the fiber - reinforced 310 of the cooling block 300 .
plastic composite including reinforced fiber in the form of [ 0279 ] Consequently, the battery module BM for the elec
long fiber and the fiber - reinforced plastic composite includ tric car is cooled through heat exchange through the heat
ing reinforced fiber in the form of fabric may be integrally dissipation plate 200 having thermal conductivity, and is
formed through injection molding, thus forming the cooling supported by the battery case including the heat dissipation
block 300 . plate 200 , the cooling block 300 , the adhesive layer 600 , and
[ 0265 ] FIG . 24 is a sectional view schematically showing the lower protective plate 500 to simultaneously provide
the battery case in accordance with an embodiment of the robustness and structural stability.
present disclosure . [ 0280 ] FIG . 26 is a diagram schematically showing a state
[ 0266 ] The battery case remains the same as the battery in which the battery module for the electric car is coupled to
case shown in FIG . 23 except that the former further the battery case shown in FIG . 18 .
includes a fastening member. [ 0281 ] As shown in the drawing, the battery module BM
[ 0267] As shown in the drawing, the battery case includes for the electric car is coupled to the top of the battery case .
the inner frame 100 , the cooling block 300 , the adhesive [ 0282 ] To be more specific , the battery case is the same as
layer 600 , the lower protective plate 500 , and the fastening the battery case shown in FIG . 18. That is , the battery case
member 700 . includes the inner frame 100 , the first adhesive layer 610 , the
[ 0268 ] Furthermore, the cooling block 300 , the inner heat dissipation plate 200 , the second adhesive layer 620 , the
frame 100 , and the adhesive layer 600 are the same as the cooling block 300 , the lower protective plate 500 , and the
cooling block 300 , the inner frame 100 , and the adhesive
9 fastening member 700 .
layer 600 shown in FIG . 23 , and only a coupling structure [ 0283 ] Furthermore, the battery module BM for the elec
coupled with the fastening member 700 is further included . tric car is coupled to the top surface of the heat dissipation
[ 0269 ] The fastening member 700 as well as the adhesive plate 200. Thus, the battery case supports the battery module
layer 600 functions to couple the cooling block 300 and the BM , and simultaneously protects the battery module BM for
inner frame 100 , and the fastening member 700 includes the
2 the electric car from external force .
bolt 710 and the nut 720 . [ 0284 ] Furthermore , heat generated from the battery mod
[ 0270 ] The fastening hole 150 through which the bolt 710 ule BM for the electric car is transferred through the heat
passes is formed in the inner frame 100. Furthermore, the nut dissipation plate 200 , and is cooled through the cooling path
720 is coupled to the cooling block 300 opposite to the 310 of the cooling block 300 .
adhesive layer 600 . [ 0285 ] Consequently, the battery module BM for the elec
[ 0271 ] To this end, the nut 720 , the cooling block 300 , and tric car is cooled through heat exchange through the heat
the lower protective plate 500 may be integrally formed dissipation plate having thermal conductivity, and is sup
through injection molding. ported by the battery case including the inner frame 100 , the
US 2021/0351455 A1 Nov. 11 , 2021
12

first adhesive layer 610 , the heat dissipation plate 200 , the [ 0297] The curing temperature of the fiber -reinforced plas
second adhesive layer 620 , the cooling block 300 , the lower tic composite is similar to the initial curing temperature of
protective plate 500 , and the fastening member 700 to the adhesive. Thus, in the case of co -bonding, when the
simultaneously provide robustness and structural stability . fiber -reinforced plastic composite is deformed while being
[ 0286 ] FIG . 27 is a sectional view schematically showing heated and pressed , it is possible to prevent the adhesive
the battery case in accordance with an embodiment of the layer from being damaged .
present disclosure. [ 0298 ] The support layer 30 may include matrix resin and
[ 0287] As shown in the drawing, the battery case includes reinforced fiber in the form of long fiber or reinforced fiber
the metal frame 100 , the adhesive layer 600 , and a support in the form of fabric woven with continuous fiber
layer 30 . [ 0299 ] The metal frame 100 may be made of aluminum .
[ 0288 ] To be more specific, the adhesive layer 600 is [ 0300 ] FIG . 28 is a sectional view schematically showing
laminated on the top of the metal frame 100 , and the support the battery case in accordance with an embodiment of the
layer 30 is laminated on the top of the adhesive layer 120 . present disclosure , and FIG . 29 is a schematic bottom view
The metal frame 100 may be the above -described inner of the battery case shown in FIG . 28 .
frame or outer frame, the support layer 30 may be made of [ 0301 ] As shown in the drawing, the battery case includes
a fiber - reinforced plastic composite, and the uneven cooling the metal frame 100 , the adhesive layer 600 , and a compos
path may be formed on the support layer 30 , thus forming ite -material layer 300 .
the above -described cooling block . [ 0302 ] To be more specific, the composite -material layer
[ 0289 ] That is , the adhesive layer 600 is interposed 300 covers at least a part of the upper portion of the metal
between the metal frame 100 and the support layer 30 , and frame 100 and covers at least a part of the lower portion of
couples the metal frame 100 and the support layer 30 . the metal frame 100 in a laminating direction .
[ 0290 ] The adhesive layer 600 may use the adhesive for a [ 0303 ] FIGS . 28 and 29 shown an example, in which the
structure , so that the robustness of the battery case 10 may composite -material layer 300 covers the upper portion of the
be increased . metal frame 100 and covers a part of the lower portion of the
[ 0291 ] In an embodiment, after the metal frame 100 and metal frame 100 .
the support layer 30 are individually manufactured , they [ 0304 ] Thus, the composite -material layer 300 includes a
may be coupled by the adhesive layer 600. In another top surface portion 301 , a side surface portion 302 , and a
embodiment, the metal frame 100 , the adhesive layer 600 , bottom surface portion 303. The top surface portion 301
and the support layer 30 are laminated in a mold , and then covers the top of the metal frame 100 , the side surface
may be coupled to each other through co -bonding. portion 302 covers the side of the metal frame 100 , and the
[ 0292 ] Thus, it is possible to form the support layer 30 and bottom surface portion 303 covers the bottom of the metal
perform a coupling process with the metal frame 100 by a frame 100 .
single process without performing an additional process for [ 0305 ] The top surface portion 301 , the side surface por
coupling the metal frame 100 and the support layer 30 . tion 302 , and the bottom surface portion 303 are integrally
[ 0293 ] In the case of performing the co -bonding, the formed .
adhesive may be a semi - cured adhesive. Although a liquid [ 0306 ] Furthermore, the bottom surface portion 303 may
adhesive may be used , its flowability is not controlled when
the adhesive is introduced into a process , so that the adhe be formed of a plurality of ribs connecting one side of the
sive may be applied to aa unwanted or unnecessary portion side surface portion 302 and the other side thereof.
and it may be difficult to form a uniform adhesive surface [ 0307 ] FIG . 30 is a process diagram schematically show
during the process . In the case of using the semi- cured ing a method of manufacturing a battery case using the
adhesive, it is easy to form a uniform adhesive surface . co - bonding of the present disclosure.
( 0294 ] In the case of performing the co - bonding , the initial [ 0308 ] As shown in the drawing, the method of manufac
curing temperature of the adhesive forming the adhesive turing the battery case includes a metal frame loading step
layer 600 may be in the range of -10 ° C. to + 10 ° C. of the S110 , an adhesive laminating step S120 , a fiber -reinforced
curing temperature of the fiber - reinforced plastic composite plastic composite ( FRP) loading step S130 , and a heating
forming the support layer 30. More preferably, the initial and pressing step S140 .
curing temperature of the adhesive may be in the range of [ 0309 ] Meanwhile , unlike a sequence shown in the draw
-5 ° C. to + 5 ° C. of the curing temperature of the fiber ing , the method of manufacturing the battery case may
reinforced plastic composite. include a fiber - reinforced plastic composite ( FRP ) loading
[ 0295 ] Here, the initial curing temperature of the adhesive step of loading a fiber - reinforced plastic composite in a
may be defined as temperature at which adhesive strength lower mold, an adhesive laminating step of laminating an
becomes 60 % compared to a case where the adhesive is fully adhesive on the fiber -reinforced plastic composite loaded in
cured . The adhesive strength may be evaluated with AS TM the lower mold , a metal frame loading step of loading a
D3163 . metal frame on the adhesive , and a heating and pressing step
[ 0296 ] To be more specific, the initial curing temperature of simultaneously imparting heat and pressure to the fiber
is temperature at which adhesive strength becomes 60 % reinforced plastic composite , the adhesive , and the metal
compared to a fully cured adhesive when curing is per frame.
formed for 1 minute per 1 mm thickness of the fiber [ 0310 ] To be more specific , the metal frame loading step
reinforced plastic composite. For example, when manufac S110 is the step of loading the metal frame in the lower
turing a fiber - reinforced plastic composite having the final mold .
thickness of 2 mm , curing of 60 % is made if a curing [ 0311 ] The adhesive laminating step S120 is the step of
operation is performed for two minutes at initial curing laminating the adhesive on the metal frame loaded in the
temperature. lower mold .
US 2021/0351455 A1 Nov. 11 , 2021
13

[ 0312 ] The fiber - reinforced plastic composite ( FRP ) load and FIG . 33 is aa bottom view schematically showing another
ing step S130 is the step of loading the fiber - reinforced embodiment of the lower mold shown in FIG . 31 .
plastic composite on the adhesive laminated on the metal [ 0323 ] As shown in the drawing, the metal frame 100 , the
frame. Considering that the fiber -reinforced plastic compos adhesive layer 600 , and the composite -material layer 300 are
ite is changed by heat and pressure , the composite may be sequentially laminated in the lower mold 50 .
loaded to cover a portion which is 60% or more and is less [ 0324 ] Furthermore, the composite -material layer 300 is
than 100% of the entire upper surface of the adhesive. In the made of a fiber -reinforced plastic composite. When the
case of covering the entire surface with the adhesive , an lower mold 50 is pressed by the upper mold 60 , the
adhesive layer and an adhered layer are deformed during the fiber - reinforced plastic composite forming the composite
co -bonding process , so that the adhesive may be applied to material layer 300 flows to cover at least a part of the metal
areas other than the adhered area of the final product. frame 100 .
Further, the thickness of the composite -material layer may [ 0325 ] To this end, as shown in FIG . 33 , the rib forming
be adjusted by adjusting a loading amount. groove 51 is formed on the lower mold 50 .
[ 0313 ] Furthermore, the initial curing temperature of the [ 0326 ] As the metal frame 100 , the adhesive layer 600 ,
adhesive forming the adhesive layer may be in the range of and the composite -material layer 300 are subjected to co
-10 ° C. to + 10 ° C. of the curing temperature of the fiber bonding using the upper and lower molds , the battery case
reinforced plastic composite. The curing temperature of the shown in FIGS . 28 and 29 may be completed.
fiber -reinforced plastic composite may range from 130 to [ 0327] A case where the cooling block and the outer frame
150 ° C. In this case , the initial curing temperature of the are coupled by both the adhesive and the co -bonding accord
adhesive may range from 120 to 160 ° C. Since the curing ing to this embodiment is much stronger in adhesive strength
temperature of the fiber - reinforced plastic composite is compared to a case where the cooling block and the outer
similar to the initial curing temperature of the adhesive, it is frame are simply attached to each other by the adhesive . A
possible to prevent the adhesive layer from being damaged conventional method where the frame of an aluminum
when the fiber - reinforced plastic composite is deformed material and the cooling block of an aluminum material are
while being heated and pressed. coupled to each other by welding may be higher in coupling
[ 0314 ] The heating and pressing step S140 is the step of force than this embodiment, but may be much heavier in
heating and pressing the metal frame, the adhesive, and the weight of the battery case than this embodiment.
fiber - reinforced plastic composite . To this end, while the [ 0328 ] FIG . 34 is a configuration diagram schematically
lower mold in which the metal frame, the adhesive, and the showing a battery case for a vehicle in accordance with an
fiber - reinforced plastic composite are loaded is combined embodiment of the present disclosure .
with an upper mold , the metal frame, the adhesive , and the [ 0329 ] As shown in the drawing, the battery case for the
fiber - reinforced plastic composite are heated and pressed . vehicle includes the support part 30 , the inner frame 100 ,
[ 0315 ] As described above, the method of manufacturing and a coupling member 700 .
the battery case may heat and press the metal frame, the [ 0330 ] To be more specific, the support part 30 is aa lower
adhesive , and the fiber - reinforced plastic composite which case of the battery case to support the battery module seated
are laminated , thus co -bonding these components. on a side thereof. The support part 30 may correspond to the
[ 0316 ] Furthermore , at the fiber - reinforced plastic com above - described cooling block if the uneven cooling path is
posite ( FRP ) loading step and the heating and pressing step , formed on the top surface of the support part.
the SMC may cover the side of the metal frame. [ 0331 ] The support part 30 includes the battery -module
[ 0317] The lower mold has a rib forming groove . At the seat part 200 and a frame coupling part 340. The battery
fiber - reinforced plastic composite (FRP ) loading step and module seat part 200 may correspond to the above - described
the heating and pressing step , the fiber - reinforced plastic heat dissipation plate, and the frame coupling part 340 may
composite may flow into the rib forming groove, and the rib correspond to the above -described spacer.
covering the bottom of the metal frame may be formed . [ 0332 ] The support part 30 may be made of a fiber
[ 0318 ] Thus, the formation of the structure of the battery reinforced plastic composite , and the inner frame 100 may
case and the coupling process may be simultaneously real be made of a metal material.
ized by a single process . [ 0333 ] The inner frame 100 is coupled to the frame
[ 0319 ] FIG . 31 is a diagram schematically showing the
coupling part 340 , and partitions the battery -module seat
co - bonding process in the manufacturing process shown in part 200 for the entire area of the support part 30 .
FIG . 30 . [ 0334 ] Furthermore, the inner frame 100 limits the move
ment of the battery module seated in the battery -module seat
[ 0320 ] As shown in the drawing, in order to form the part 200 , and supports the battery module against external
battery case by heating and pressing , the metal frame 100 , force .
the adhesive layer 600 , and the support layer 30 are sequen [ 0335 ] The inner frame 100 includes the first inner frame
tially laminated in the lower mold 50 . 110 , the second inner frame 120 , and the third inner frame
[ 0321 ] While the upper mold 60 is combined with the 130 .
lower mold 50 , the metal frame 100 , the adhesive layer 600 , [ 0336 ] The first inner frame 110 is located in the support
and the support layer 30 are pressed. In this case , in order to part 30 , and extends in one - axis direction .
heat the metal frame 100 , the adhesive layer 600 , and the [ 0337] The second inner frame 120 extends coaxially with
support layer 30 , a process of heating at least one of the the first inner frame 110 , and is located on the edge of the
lower mold 50 and the upper mold 60 may be optionally support part 30 .
performed before or after a pressing process. [ 0338 ] That is , the second inner frame 120 is located on
[ 0322 ] FIG . 32 is aa sectional view schematically showing the edge of the support part 30 , and the first inner frame 110
>

the battery -case manufacturing process shown in FIG . 30 , is located inside the support part 30 .
US 2021/0351455 A1 Nov. 11 , 2021
14

[ 0339 ] The third inner frame 130 extends in a direction [ 0358 ] The second inner lower frame 124 extends to be
perpendicular to the first inner frame 110 and the second parallel to a surface of the support part 30 and comes into
inner frame 120 . contact with the support part 30 , and the second inner lower
[ 0340 ] Hereinafter, the detailed shape and organic cou frame 124 is coupled to the support part 30 by the coupling
pling relationship of the inner frame will be described in member 730 .
detail with reference to FIGS . 35 to 39 . [ 0359 ] The second inner upper frame 122 is formed to
[ 0341 ] FIG . 35 is a sectional view showing a coupling protrude from the second inner lower frame 124 .
portion between the inner frame and the cooling block of the [ 0360 ] Furthermore, the coupling member 730 may com
battery case for the vehicle shown in FIG . 34 . prise a self piercing rivet.
[ 0342 ] As shown in the drawing, the first inner frame 110 [ 0361 ] Thus, the second inner frame 120 may be coupled
includes a first inner protruding frame 112 and a first inner to the support part 30 even in a narrow space .
supporting frame 114. [ 0362 ] FIG . 38 is a schematic sectional view of the first
[ 0343 ] To be more specific, the first inner protruding frame inner frame of the battery case for the vehicle in accordance
112 protrudes from the first inner supporting frame 114 . with an embodiment of the present disclosure.
Furthermore, the first inner supporting frame 114 extends to [ 0363 ] As shown in the drawing, the first inner frame 110
be parallel to a surface of the support part 30 . is fixedly coupled to the support part 30 by the adhesive .
[ 0344 ] The adhesive 600 may be applied between the first [ 0364 ] To be more specific , the first inner frame 110
inner supporting frame 114 and the support part 30 to couple includes the first inner protruding frame 112 and the first
the first inner supporting frame and the support part. inner supporting frame 114 .
[ 0345 ] FIG . 36 is aa schematic sectional view taken along [ 0365 ] The first inner protruding frame 112 protrudes from
line A - A of the first inner frame of the battery case for the the first inner supporting frame 114. Furthermore, the first
vehicle shown in FIG . 34 . inner supporting frame 114 extends to be parallel to a surface
[ 0346 ] As shown in the drawing, the first inner frame 110 of the support part 30 .
includes the first inner protruding frame 112 and the first [ 0366 ] The support part 30 includes the frame coupling
inner supporting frame 114 . part 340 formed at a position corresponding to the first inner
[ 0347] To be more specific, the first inner protruding frame protruding frame 112 to protrude upwards from the support
112 protrudes from the first inner supporting frame 114 . part 30.
Furthermore, the first inner supporting frame 114 extends to [ 0367] The first inner supporting frame 114 is opposite to
be parallel to a surface of the support part 30 . the support part 30 , and the first inner protruding frame 112
[ 0348 ] A coupling -member through hole 113 is formed in is opposite to the frame coupling part 340 .
the first inner protruding frame 112 . [ 0368 ] Furthermore, the adhesive may be applied to a side
[ 0349 ] The frame coupling part 340 is formed at a position of the frame coupling part 340 to form aa first attaching part
corresponding to the first inner protruding frame 112 to 610 , and the adhesive may be applied to the support part 30
protrude upwards from the support part 30. This frame to form a second attaching part 620 .
coupling part 340 may correspond to the above - described [ 0369 ] Thus, the first inner frame 110 is fixedly coupled to
spacer.
[ 0350 ] The support part 30 is opposite to the first inner the frame coupling part 340 of the support part 30 , thus
supporting frame 114 , and the frame coupling part 340 is realizing both robustness and lightness .
opposite to the first inner protruding frame 112 . [ 0370 ] FIG . 39 is a schematic sectional view of the first
[ 0351 ] Corresponding coupling members are coupled to inner frame of the battery case for the vehicle in accordance
the frame coupling part 340 and the first inner protruding with an embodiment of the present disclosure.
frame 112 , respectively. [ 0371 ] The battery case for the vehicle in accordance with
[ 0352 ] For example, FIG . 36 shows an example where the an embodiment of the present disclosure shown in the
first coupling member, i.e. the bolt 710 is coupled to the drawing remains the same as the battery case for the vehicle
frame coupling part 340 , and the second coupling member, shown in FIGS . 34 and 36 except for the coupling structure
i.e. the nut 720 is coupled to the first inner protruding frame between the first inner frame and the frame coupling part.
112 . [ 0372 ] To be more specific , the first inner frame 110
[ 0353 ] Furthermore , the bolt 710 may be coupled to the includes the first inner protruding frame 112 and the first
frame coupling part 340 that is the fiber -reinforced plastic inner supporting frame 114 .
composite by insert molding. [ 0373 ] The coupling -member through hole 113 is formed
[ 0354 ] The first inner supporting frame 114 is fixedly in the first inner protruding frame 112 .
coupled to the support part 30 by the adhesive 600 that is a [ 0374 ] The frame coupling part 340 is formed at a position
bonding material. corresponding to the first inner protruding frame 112 to
[ 0355 ] Thus, as the first inner protruding frame 112 is protrude upwards from the support part 30 .
coupled to the frame coupling part 340 by the coupling [ 0375 ] The first inner supporting frame 114 is opposite to
member 700 and the first inner supporting frame 114 is the support part 30 , and the first inner protruding frame 112
coupled to the support part 30 by the adhesive 600 , the first is opposite to the frame coupling part 340 .
inner frame 110 is coupled to the support part 30 . [ 0376 ] The corresponding coupling members 710 and 720
[ 0356 ] FIG . 37 is a schematic sectional view taken along are coupled to the frame coupling part 340 and the first inner
line B - B of the second inner frame of the battery case for the protruding frame 112 , respectively.
vehicle shown in FIG . 34 . [ 0377] The adhesive may be applied to a side of the frame
[ 0357] As shown in the drawing, the second inner frame coupling part 340 to form the first attaching part 610 , and the
120 includes a second inner upper frame 122 and a second adhesive may be applied to the support part 30 to form the
inner lower frame 124 . second attaching part 620 .
US 2021/0351455 A1 Nov. 11 , 2021
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[ 0378 ] Thus, as the first inner protruding frame 112 is [ 0395 ] Thus, the first inner protruding frame 112 may be
coupled to the frame coupling part 340 by the coupling coupled to the frame coupling part 340 by the coupling
member 700 , and the first inner protruding frame 112 and the member, and the first inner supporting frame 114 may be
first inner supporting frame 114 are coupled to the frame coupled to the support part 30 by the adhesive 600 , and
coupling part 340 and the support part 30 , respectively, by coupled to the frame coupling part 340 by the mounting
the adhesive, a coupling force may be further increased . coupling member.
[ 0379 ] FIG . 40 is a configuration diagram schematically [ 0396 ] FIG . 42 is a configuration diagram schematically
showing the battery case for the vehicle in accordance with showing a battery case for an electric car in accordance with
an embodiment of the present disclosure , and FIG . 41 is a an embodiment of the present disclosure.
schematic sectional view taken along line C - C of the first [ 0397] As shown in the drawing, the battery case 1000 for
inner frame of the battery case for the vehicle shown in FIG . the electric car includes a support part 1100 and an inner
40 . frame 1200 .
[ 0380 ] The battery case for the vehicle in accordance with [ 0398 ] To be more specific , the support part 1100 is the
an embodiment remains the same as the battery case for the lower case of the battery case to support the battery module
vehicle shown in FIG . 34 except that the former further seated on a side.
includes a mounting part. [ 0399 ] The inner frame 1200 is coupled to the support part
[ 0381 ] As shown in the drawing, the battery case for the 1100 , and partitions the battery -module seat part 1100 for the
vehicle includes the support part 30 , the inner frame 100 , entire area of the support part 1100 .
and the coupling member 700 . [ 0400 ] Furthermore , the inner frame 1200 limits the move
[ 0382 ] To be more specific , the support part 30 includes ment of the battery module seated in the battery -module seat
the battery -module seat part 200 and the frame coupling part part 1100 , and supports the battery module against external
340. The inner frame 100 is coupled to the frame coupling force . The inner frame 1200 may be formed through an
part 340 , and partitions the battery -module seat part 200 for extrusion process , and be coupled to the support part 1100
the entire area of the support part 30 . by the adhesive ( denoted by reference numeral 1600 in FIG .
[ 0383 ] Furthermore, the inner frame 100 limits the move 43) .
ment of the battery module seated in the battery -module seat [ 0401 ] The inner frame 1200 may be made of a fiber
part 200 , and supports the battery module against external reinforced plastic composite , and particularly be made of a
force . fiber - reinforced plastic composite including continuous fiber
[ 0384 ] The inner frame 100 includes the first inner frame as reinforced fiber . Thereby, it is possible to obtain the
110 , the second inner frame 120 , and the third inner frame battery case for the electric car having mechanical strength
130 . while realizing lightness.
[ 0385 ] The first inner frame 110 further includes a mount [ 0402 ] Hereinafter, the detailed shape and organic cou
ing coupling hole , compared to the first inner frame 110 pling relationship of the inner frame will be described in
shown in FIGS . 34 and 36 . detail with reference to FIG . 43 .
[ 0386 ] That is , the first inner frame includes the first inner [ 0403 ] FIG . 43 is a schematic sectional view taken along
protruding frame 112 and the first inner supporting frame line D - D of the inner frame of the battery case for the vehicle
114 . shown in FIG . 42 .
[ 0387] In addition to the coupling -member through hole [ 0404 ] As shown in the drawing, the inner frame 1200 is
( denoted by reference numeral 113 in FIG . 3 ) , a mounting coupled to the support part 1100 by the adhesive 1600. The
inner frame 1200 includes an inner external frame 1210 and
coupling hole 113 is further formed in the first inner pro an inner internal frame 1220 .
truding frame 112. The mounting coupling hole 113 serves [ 0405 ] To be more specific, the inner external frame 1210
to fix the battery case for the vehicle to a vehicle body . forms the external body of the inner frame, and the inner
[ 0388 ] The frame coupling part 340 is formed at a position internal frame 1220 is formed inside the inner external frame
corresponding to the first inner protruding frame 112 to 1210. Furthermore, the inner internal frame 1220 may
protrude upwards from the support part 30 . comprise a reinforcing rib that connects one side of the inner
[ 0389 ] A mounting coupling part 116 is formed in the external frame 1210 and the other side thereof.
frame coupling part 340 to be opposite to the mounting [ 0406 ] For example, the inner external frame 1210 gen
coupling hole 113 . erally has the shape of “ O ” , and defines a hollow part
[ 0390 ] The mounting coupling part 116 may be a fastening therein . Furthermore, the inner internal frame 1220 spanning
groove to which a screw is fastened . the hollow part may be formed in the shape of “ 2 ” .
[ 0391 ] Thus, in a state where the mounting coupling [ 0407] Furthermore, as the inner frame 1200 is formed
member is coupled to the vehicle body, the mounting through extrusion or pultrusion molding as described above ,
coupling member may be coupled to the mounting coupling the thicknesses of the inner external frame 1210 and the
part 116 through the mounting coupling hole 113 . inner internal frame 1220 may be optionally adjusted.
[ 0392 ] Furthermore, the mounting coupling member may [ 0408 ] That is , the thickness T1 of the inner external frame
be formed in the frame coupling part 340 through insert 1210 forming the bottom may be greater than the thickness
molding, and may be fixedly coupled to the vehicle body. T2 of the inner external frame 1210 forming the side .
[ 0393 ] Corresponding coupling members (denoted by ref [ 0409 ] Furthermore, this may be implemented in various
erence numeral 700 in FIG . 36 ) are coupled to the frame ways in view of the characteristics of the battery module and
coupling part 340 and the first inner protruding frame 112 , the case mounted on the vehicle.
respectively [ 0410 ] FIG . 44 is a configuration diagram schematically
[ 0394 ] Furthermore , the first inner supporting frame 114 is showing a battery case for an electric car in accordance with
coupled to the support part 30 by the adhesive 600 . an embodiment of the present disclosure .
US 2021/0351455 A1 Nov. 11 , 2021
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[ 0411 ] As shown in the drawing, the battery case for the [ 0431 ] The inner frame body 1230 may be made of a
electric car further includes an outer frame, compared to the plastic composite reinforced by glass fiber or carbon fiber,
battery case shown in FIG . 42 . and be formed through an extrusion process .
[ 0412 ] To be more specific , the battery case for the electric [ 0432 ] The inner frame coupling body 1240 may be made
car includes a support part 1100 , an inner frame 1200 , and of aa steel or aluminum material.
an outer frame 1300 . [ 0433 ] The battery case for the electric car in accordance
[ 0413 ] Furthermore , since the support part 1100 and the with an embodiment of the present disclosure is configured
inner frame 1200 are the same as the support part 1100 and as described above , so that durability and lightness may be
the inner frame 1200 of the above -described embodiment, a attained and the processability of the mounting -bolt cou
detailed description thereof will be omitted herein . pling part may be improved .
[ 0414 ] The outer frame 1300 is coupled to the edge of the [ 0434 ] FIG . 47 is a configuration diagram schematically
support part 1100 to form the periphery of a lower case . showing the technical idea of a battery case package for a
[ 0415 ] Furthermore , the outer frame 1300 may be formed vehicle in accordance with the present disclosure .
through extrusion or pultrusion molding , and be coupled to [ 0435 ] As shown in the drawing, the battery case package
the support part 1100 by the adhesive ( denoted by reference for the vehicle includes an upper case 2100 , a battery
numeral 1600 in FIG . 45 ) . module 2200 , a lower case 2300 , and a lower protective
[ 0416 ] Hereinafter, the detailed shape and organic cou plate 2400 .
pling relationship of the inner frame will be described in
detail with reference to FIG . 45 . [ 0436 ] To be more specific , the battery module 2200 is
[ 0417] FIG . 45 is a schematic sectional view taken along seated and secured on the lower case 2300 , and the upper
line E - E of the outer frame in the battery case for the vehicle case 2100 is coupled to the top of the lower case 2300 to
shown in FIG . 44 . cover the battery module 2200 .
[ 0418 ] As shown in the drawing, the outer frame 1300 [ 0437] The lower protective plate 2400 is coupled to the
includes an outer lower support frame 1310 and an outer side bottom of the lower case 2300 .
support frame 1320 . [ 0438 ] Thus , the lower protective plate 2400 is coupled to
[ 0419 ] To be more specific , while the outer lower support the battery case including the upper case 2100 , the battery
frame 1310 supports the outer side support frame 1320 , the module 2200 , and the lower case 2300 .
outer lower support frame 1310 and the outer side support [ 0439 ] The lower protective plate 2400 is made of a
frame 1320 are integrally formed . composite material. Furthermore, the lower protective plate
[ 0420 ] The outer lower support frame 1310 is coupled to 2400 may be made of aa thermosetting plastic composite
the support part 1100 by the adhesive 1600. The inner frame material including glass fiber.
1200 may be supported in the outer lower support frame [ 0440 ] The lower case 2300 and the lower protective plate
1310 . 2400 are coupled through the coupling member. Further
[ 0421 ] That is , the inner frame 1200 may be coupled to the more , the lower protective plate 2400 of the composite
top surface C of the outer lower support frame 1310 to be material may be integrated with the lower case 2300 of the
held thereon . composite material.
[ 0422 ] In order to increase strength, an outer internal [ 0441 ] Thus , the battery case package for the vehicle may
lower support frame 1311 as the reinforcing rib may be realize lightness and protect the bottom of the battery case
formed in the outer lower support frame 1310 . for the vehicle .
[ 0423 ] In order to increase strength , an outer internal side [ 0442 ] FIG . 48 is a configuration diagram schematically
support frame 1321 as the reinforcing rib may be formed in showing a lower case and a lower protective plate, in the
the outer side support frame 1320 . battery case package for the vehicle in accordance with an
[ 0424 ] That is , the outer lower support frame 1310 defines embodiment of the present disclosure , and FIG . 49 is a
a hollow part therein , and the outer internal lower support schematic sectional view taken along line F - F of the lower
frame 1311 spans the hollow part. The outer side support protective plate shown in FIG . 48 .
frame 1320 defines a hollow part therein , and the outer [ 0443 ] As shown in the drawing, in order to protect the
internal side support frame 1321 spans the hollow part. battery case , the lower protective plate 2400 is coupled to
[ 0425 ] FIG . 46 is a configuration diagram schematically .

the bottom of the lower case 2300. Furthermore, a coupling

showing a battery case for an electric car in accordance with member 2500 couples the lower case 2300 and the lower
an embodiment of the present disclosure . protective plate 2400 .
[ 0426 ] The battery case for the electric car remains the [ 0444 ] To be more specific , the lower case 2300 serves to
same as the battery case for the electric car according to the the battery module seated thereon , and includes a battery
preceding embodiment, except for only the structure of the module seat part 2310 on which the battery module is fixedly
inner frame.
[ 0427] To be more specific , the battery case for the electric seated, and a frame part 2320 .
car includes the support part 1100 , the inner frame 1200 , and [ 0445 ] The frame part 2320 includes a body frame 2321 ,
the outer frame 1300 . a support frame 2322 , and an extension frame 2323 .
[ 0428 ] The inner frame 1200 includes an inner frame body [ 0446 ] The support frame 2322 is coupled to the body
1230 and an inner frame coupling body 1240 . frame 2321 to partition the battery -module seat part 2310 for
[ 0429 ] The inner frame body 1230 has the same sectional the entire area of the body frame 2321 .
shape as the inner frame 1200 shown in FIG . 43 . [ 0447] The extension frame 2323 extends outwards from
[ 0430 ] The inner frame coupling body 1240 is coupled to the body frame 2321 , and a lower -protective-plate coupling
the inner frame body 1230 , and has a mounting -bolt cou part 2323a is formed to correspond to the coupling member
pling part 1241 to be coupled to the vehicle body. 2500 .
US 2021/0351455 A1 Nov. 11 , 2021
17

[ 0448 ] The lower protective plate 2400 includes a plate part 2410 supports the bottom of the cooling path 2321a , and
part 2410 and a protruding support part 2420 , and an. the protruding support part 2420 supports the bottom of the
extension coupling part 2411 is formed on the plate part space 2321b.
2410 . [ 0462 ] Thus , the lower protective plate 2400 may be in
[ 0449 ] The plate part 2410 corresponds to the body frame close contact with the lower case 2300 to be secured thereto .
2321 , and the protruding support part 2420 is coupled to the [ 0463 ] FIG . 51 is a configuration diagram schematically
plate part 2410 or extends from the plate part 2410 . showing the lower protective plate in accordance with an
[ 0450 ] Furthermore , the protruding support part 2420 may embodiment of the present disclosure .
protrude to be opposite to the lower case 2300. When the [ 0464 ] As shown in the drawing, the lower protective plate
lower protective plate 2400 is coupled to the lower case 2400 further includes a mounting coupling part, compared to
2300 , the protruding support part 2420 prevents a gap the lower protective plate 2400 shown in FIG . 48 .
between the lower case 2300 and the lower protective plate [ 0465 ] To be more specific , the lower protective plate
2400 from increasing , and serves as a damping when exter 2400 includes a plate part 2410 and a protruding support part
nal force is applied thereto . 2420 , and an extension coupling part 2411 is formed on the
2

[ 0451 ] The extension coupling part 2411 is formed to plate part 2410 .
correspond to the extension frame 2323 , and the lower - case [ 0466 ] Furthermore, the mounting coupling part 2412 is
coupling part 2411a corresponding to the lower -protective formed on the plate part 2410. The mounting coupling part
plate coupling part 2323a is formed on the extension cou 2412 couples the battery case package for the vehicle to the
pling part 2411 . vehicle body . To this end, coupling holes corresponding to
the mounting coupling part 2412 may be formed in the upper
[ 0452 ] The lower protective plate 2400 may be made of a case and the lower case , respectively .
composite material. Furthermore, the lower protective plate [ 0467] Next, the material of each of components forming
2400 may be made of a fiber - reinforced plastic composite. the battery case of the present disclosure will be described .
[ 0453 ] The plate part 2410 may be made of a fiber [ 0468 ] The inner frame 100 may be made of a material
reinforced plastic composite (woven SMC ) including rein having high stiffness, such as metal or a fiber - reinforced
forced fiber in the form of fabric , and the protruding support plastic composite, to ensure the structural stiffness of the
part 2420 may be made of a fiber - reinforced plastic com entire battery case 10 .
posite ( chop SMC ) including reinforced fiber in the form of [ 0469 ] The metal material may be any one selected from
long fiber. a group consisting of, particularly, iron, stainless steel ,
[ 0454 ] Furthermore, as the protruding support part 2420 is aluminum , copper, brass , nickel , zinc , and alloy thereof, and
made of aa fiber -reinforced plastic composite including rein elements constituting the metal may be mainly composed of
forced fiber in the form of long fiber, the protruding support iron or aluminum . In this regard, the expression “ mainly
part may more efficiently perform the damping of the battery composed ” means that anything occupies 90 wt % or more .
case . [ 0470 ] In particular, steel such as general structural rolled
[ 0455 ] Thus, the protruding support part 2420 may be steel ( SS ) , cold - rolled steel ( SPCC ) , or high - tensile material
optionally formed in some area of the plate part 2410 having (high - tensile steel ) , stainless steel such as SUS304 or
strong vibration , compared to other areas. SUS316 , aluminum of 1000 to 700 series, and alloy thereof
[ 0456 ] The coupling member 2500 may be implemented are suitable . Furthermore , the metal material may be made
in various ways to couple the lower -protective -plate cou of two or more types of metal, or be metal -plated on a
pling part 2323a and the lower - case coupling part 2411a . surface thereof.
[ 0457] Furthermore , in FIG . 48 , as an example of the [ 0471 ] The heat dissipation plate 200 may be made of a
coupling member 2500 , the lower -protective -plate coupling metal material having high thermal conductivity.
part 2323a , and the lower- case coupling part 2411a , the [ 0472 ] The metal material may be any one selected from
lower -protective -plate coupling part 2323a and the lower a group consisting of, particularly, iron , stainless steel ,
case coupling part 2411a may be composed of through aluminum , copper, brass , nickel , zinc , and alloy thereof,and
holes , and the coupling member 2500 may be composed of elements constituting the metal may be mainly composed of
a bolt 2510 and a nut 2520 , which are inserted into a iron or aluminum . In this regard , the expression “ mainly
coupling hole . composed ” means that anything occupies 90 wt % ormore .
[ 0458 ] The battery case package for the vehicle in accor [ 0473 ] In particular, the metal material is preferably made
dance with an embodiment of the present disclosure is of aluminum of 1000 to 700 series and alloy thereof, in terms
configured as described above . As the lower -protective -plate of heat dissipation performance.
coupling part 2323a and the lower - case coupling part 2411a [ 0474 ] The outer frame 400 may be made of a material
are coupled by the coupling member 2500 , the lower pro having high stiffness, such as metal or a fiber - reinforced
tective plate 2400 is coupled to the lower case 2300 . plastic composite, to ensure the structural stiffness of the
entire battery case 10 .
[ 0459 ] FIG . 50 is aa sectional view schematically showing [ 0475 ] The metal material may be any one selected from
an embodiment in which the lower case and the lower a group consisting of, particularly, iron , stainless steel ,
protective plate shown in FIG . 48 are coupled to each other. aluminum , copper, brass , nickel , zinc , and alloy thereof, and
[ 0460 ] As shown in the drawing, cooling paths 2321a are elements constituting the metal may be mainly composed of
formed on the body frame 2321 of the lower case 2300 to iron or aluminum . In this regard, the expression “ mainly
cool the battery module. Furthermore , a space 2321b is composed ” means that anything occupies 90 wt % ormore .
defined between the cooling paths 2321a . [ 0476 ] In particular, steel such as general structural rolled
[ 0461 ] The plate part 2410 and the protruding support part steel ( SS ) , cold - rolled steel ( SPCC ) , or high - tensile material
2420 are formed on the lower protective plate 2400 , the plate (high -tensile steel ) , stainless steel such as SUS304 or
US 2021/0351455 A1 Nov. 11 , 2021
18

SUS316 , aluminum of 1000 to 700 series, and alloy thereof thickness of 2 mm , curing of 60 % is made if a curing
are suitable . Furthermore, the metal material may be made operation is performed for two minutes at initial curing
of two or more types of metal, or be metal - plated on a temperature.
surface thereof. [ 0485 ] The curing temperature of the fiber -reinforced plas
[ 0477] The adhesive may be any one selected from a tic composite may range from 130 to 150 ° C. In this case , the
group consisting of an acrylic adhesive, an epoxy adhesive, initial curing temperature of the adhesive may range from
an urethane adhesive, an olefin adhesive, an EVA ( Ethylene 120 to 160 ° C. , and more preferably, range from 125 to 1550
vinyl acetate ) adhesive, a silicon adhesive, and a mixture C.
thereof, and may include a thermoplastic component and a [ 0486 ] The curing temperature of the fiber - reinforced plas
thermosetting component, for example. tic composite is similar to the initial curing temperature of
[ 0478 ] The thermoplastic component of the adhesive may the adhesive . Thus, when the fiber -reinforced plastic com
be a thermoplastic polymer, e.g. polyolefin such as polyeth posite is deformed while being heated and pressed , it is
ylene or polypropylene . Furthermore , the thermoplastic possible to prevent the adhesive layer from being damaged.
component of the adhesive may be any one selected from a [ 0487] When the initial curing temperature of the adhesive
group consisting of polystyrene, acrylonitrile styrene, buta is less than 120 ° C. , the thermal curing process of the
diene , polyethylene terephthalate, polybutylene terephtha adhesive is started and ended prior to that of the fiber
late , polybutylene tetrachlorate , polyvinyl chloride, plasti reinforced plastic composite, thus causing a reduction in
cized polyvinyl chloride , unplasticized polyvinyl chloride, adhesive strength due to the deterioration, internal stress, or
and a mixture thereof. surface fracture of the adhesive. When the initial curing
[ 0479 ] Furthermore, the thermoplastic component of the temperature of the adhesive is more than 160 ° C. , the
adhesive may be any one selected from a group consisting adhesive may not be sufficiently cured after the thermal
of polyarylene ether, polycarbonate, polyester carbonate , curing process of the fiber -reinforced plastic composite .
thermoplastic polyester, polyimide, polyetherimide, poly [ 0488 ] If the metal material and the fiber - reinforced plastic
amide , acrylonitrile -butylacrylate - styrene polymer, amor composite are attached using the adhesive, the shear strength
phous nylon , polyarylene ether ketone, polyphenylene sul ( lap shear) of the metal material and the fiber - reinforced
fide, polyaryl sulfone, polyether sulfone , liquid crystal plastic composite may be 5 MPa or more , and particularly
polymer, poly ( 1,4 -phenylene) compound, polycarbonate, range from 7 MPa to 10 MPa . In this case , the shear strength
nylon, silicon , and a mixture thereof. may be measured according to ASTM D 1002 .
[ 0480 ] The thermosetting component of the adhesive may [ 0489 ] The cooling block 300 may be made of a material
be any one selected from a group consisting of a material such as a fiber - reinforced plastic composite , aluminum or
containing one or more epoxy groups, epoxide, epoxy resin , steel , and be made of a fiber reinforced plastic (FRP )
epoxy adhesive, polyester, polyester resin , thermosetting composite as an embodiment for realizing lightness.
urethane, thermosetting polyurethane, diallyl -phthalate , [ 0490 ] The matrix resin combined with the reinforced
polyimide, polyamide , cyanate ester, polycyanurate, and a fiber may be any one selected from a group consisting of
mixture thereof. thermoplastic resin , curable resin , and a mixture thereof.
[ 0481 ] As for a weight ratio of the thermoplastic compo [ 0491 ] The thermoplastic resin may be any one selected
nent and the thermosetting component which are used as the from a group consisting of polyethylene resin ( PE ) , poly
adhesive , in some examples, the content of the thermoplastic propylene resin (PP ) , polymethylpentene resin ( PMP ) , poly
component may be higher than the content of the thermo vinyl chloride resin ( PVC ), polystyrene resin (PS ) , acryloni
setting component . For example, the adhesive may contain trile /butadiene /styrene copolymer ( ABS ) , polymethyl
the thermosetting component less than 10 wt % or 5 wt % methacrylate resin (PMMA ), polyamide resin (PA ), poly
in the total weight of the adhesive. Although the thermoset ethylene terephthalate resin (PET), polybutylene terephtha
ting component may improve the adhesive strength of the late resin (PBT ) , polycarbonate resin (PC ) , modified poly
fiber - reinforced plastic composite, it is preferable that an phenylene ether resin (modified PPE ) , polyether sulfone
excessive amount of thermosetting component is not con resin ( PES ) , polyimide resin ( PI ) , polyetherimide resin
tained to thermoform or form the fiber - reinforced plastic (PEI ) , polyether nitrile resin (PEN) , polyacetal resin (POM) ,
composite . polyphenylene sulfide resin ( PPS ) , polyether ketone resin
[ 0482 ] Meanwhile, in the case of performing the co (PEK) , polyether ether ketone resin (PEEK) , polyphenyl
bonding, the initial curing temperature of the adhesive may sulfone resin (PPSU ) , polyphthalamide resin (PPA ), and a
be in the range of -10 ° C. to + 10 ° C. of the curing mixture thereof .
temperature of the fiber -reinforced plastic composite . More [ 0492 ] The curable resin may be any one selected from a
preferably, the initial curing temperature of the adhesive group consisting of thermosetting resin , photocurable resin
may be in the range of -5 ° C. to + 5 ° C. of the curing (e.g. ultraviolet curable resin) , moisture curable resin , and a
temperature of the fiber -reinforced plastic composite. mixture thereof .
[ 0483 ] Here, the initial curing temperature of the adhesive [ 0493 ] The thermosetting resin exhibits fluidity at room
may be defined as temperature at which adhesive strength temperature, and is not limited to specific resin as long as it
becomes 60 % compared to a case where the adhesive is fully is curable when being heated . For example, the thermoset
cured . ting resin may be any one selected from a group consisting
[ 0484 ] To be more specific, the initial curing temperature of polyurethane resin, unsaturated polyester resin , phenol
is temperature at which adhesive strength becomes 60 % resin , urea resin , epoxy resin , vinyl ester resin , melamine
compared to a fully cured adhesive when curing is per resin , acryl resin , polybutadiene resin , silicon resin , and a
formed for 1 minute per 1 mm thickness of the fiber mixture thereof.
reinforced plastic composite. For example, when manufac [ 0494 ] The photocurable resin may use a composition
turing a fiber -reinforced plastic composite having the final including a radical polymerizable component, a photo radi
US 2021/0351455 A1 Nov. 11 , 2021
19

cal polymerization initiator, a cationic polymerizable com synthetic organic fiber, high modulus organic fiber, e.g.
ponent , and a photo cationic polymerization initiator . para -aramid fiber or meta -aramid fiber, nylon fiber, poly
[ 0495 ] The moisture curable resin may include urethane propylene fiber, polyethylene fiber, polyethylene terephtha
resin , silicon resin containing an alkoxide group , etc. As an late fiber, polybutylene terephthalate fiber, or polyester fiber,
example of the moisture curable resin , a urethane polymer natural fiber, e.g. hemp, jute, flax , coir, kenaf or cellulose
containing an isocyanate group at the end of a molecule may fiber, mineral fiber, e.g. basalt , mineral wool (e.g. rock wool
be used as the main component, and the isocyanate group or slag wool ) , wollastonite , alumina or silica , metal fiber,
may react with water to form a cross - linked structure . metal- treated natural fiber or synthetic fiber, ceramic fiber,
[ 0496 ] Furthermore, the matrix resin may contain various yarn fiber, and a mixture thereof.
additives which are generally mixed with resin , such as a ( 0504 ] For instance, a sheet produced by combining the
flame retardant, a coupling agent, a conductivity imparting matrix resin and the reinforced fiber may be in the shape of
agent, an inorganic filler, an ultraviolet absorber, an anti a first sheet including the matrix resin and the long fiber as
oxidant, dye, and pigment. the reinforced fiber. The first sheet is configured such that the
[ 0497] The flame retardant may use a bromine flame long fiber is dispersed in the matrix resin .
retardant. Examples of the bromine flame retardant may [ 0505 ] The first sheet includes long fiber which is superior
include decabromodiphenyl ether, tetrabromo bisphenol A , in flowability and formability to the continuous fiber, thus
tetrabromo bisphenol S , 1,2 -bis( 2,3,4,5',6 '- pentabrom exhibiting excellent processability when the fiber - reinforced
ophenyl ) ethane, 1,2 -bis(2,4,6 -triblomophenoxy Jethane , 2,4 , plastic composite is manufactured . The long fiber means
6 - tris (2,4,6 - bromophenoxy )-1,3,5 - triazine, 2,6 -dibrom fiber that is shorter in length than continuous fiber and is cut
ophenol, 2,4 - dibromophenol, bromine polystyrene, ethylene to a predetermined length .
bistetrabromophthalic acid imide , hexabromo cyclodode ( 0506 ] The first sheet may include 20 to 70 parts by
cane , hexabromo benzene, pentabromo benzyl acrylate, 2,2 weight, and particularly 40 to 50 parts by weight of long
bis [4'(2',3 "-dibromopropoxy )-3',5'-dibromophenyl] -pro fiber, on the basis of 100 parts by weight of the matrix resin .
pane, bis ( 3,5 -dibromo, 4 -bromorpropoxy phenyl) sulfone, The basis weight of the long fiber may range from 1500 g /m²
tris ( 2,3 - dibromopropyl ) isocyanurate , etc. to 3500 g /m². When the content of the long fiber is less than
[ 0498 ] The bromine flame retardant may be contained in 20 parts by weight, it is difficult to expect the mechanical
the amount of 0.4 to 25 parts by weight, and particularly 5 strength of the fiber -reinforced plastic composite . When the
to 15 parts by weight, on the basis of 100 parts by weight of content is more than 70 parts by weight, the content of the
the matrix resin . When the content of the bromine flame long fiber is increased , so that it is difficult to realize the
retardant is less than 0.4 parts by weight, combustion time lightness of the fiber - reinforced plastic composite, and form
tends to be longer. When the content of the bromine flame ability may be reduced .
retardant is more than 25 parts by weight, the specific [ 0507] The long fiber may have the average length of 10
gravity of a molded product may be increased or the flame mm to 30 mm , and particularly 10 mm to 20 mm . When the
retardant may flow out of a surface of the molded product. average length of the long fiber is less than 10 mm , manu
[ 0499 ] Furthermore, the flame retardant may use an anti facturing cost may be reduced but mechanical properties
mony flame retardant. Examples of the antimony flame may be deteriorated . In contrast, when the average length of
retardant may include antimony trioxide, antimony tetraox the long fiber is more than 30 mm , it may be difficult for the
ide , antimony penta -oxide, sodium pyroantimonate, anti fiber to be dispersed in the matrix resin, and formability may
mony trichloride, antimony trisulfide, antimony oxychloride be deteriorated.
or potassium antimonite .
[ 0500 ] The antimony flame retardant may be contained in [ 0508 ] Furthermore, the section diameter of the long fiber
the amount of 0.2 to 12.5 parts by weight, and particularly may range from 5 pm to 30 um . When the section diameter
1 to 3 parts by weight, on the basis of 100 parts by weight of the long fiber satisfies this range , it is possible to attain the
of the matrix resin . When the content of the antimony flame mechanical strength and formability of the fiber -reinforced
retardant is less than 0.2 parts by weight, combustion time plastic composite .
tends to be longer. When the content of the antimony flame [ 0509 ] By adjusting the average length , section diameter,
retardant is more than 12.5 parts by weight, the specific and content of the long fiber, the first sheet may be made to
gravity of the fiber - reinforced plastic composite may be the thickness of about 0.1 mm to 10 mm . In this range, it is
increased possible to attain the excellent mechanical strength and
[ 0501 ] Furthermore, the flame retardant may further formability and shock absorbing properties.
include aluminum hydroxide. In this case , the aluminum [ 0510 ] The first sheet may be made in the following
hydroxide may be contained in the amount of 5 to 20 parts method. First , the matrix resin is put into a compounding
by weight, on the basis of 100 parts by weight of the matrix extruder, and the reinforced fiber pulled out from a plurality
resin . The aluminum hydroxide is not volatilized by heat but of roving type of yarn bunches is put into a middle part of
is decomposed to release water and non - flammable gas . It the compounding extruder. Subsequently , the reinforced
cools the fiber - reinforced plastic composite through endo fiber is cut to a predetermined length , and simultaneously the
thermic reaction on the surface of the fiber - reinforced plastic cut fiber and the preheated matrix resin are mixed . Subse
composite , and plays a role in reducing the production of a quently, a strand type of long fiber may be discharged , and
pyrolysate. then be compressed and formed in the mold to manufacture
[ 0502 ] The flame retardant may be added to a mixture the first sheet .
including reinforced fiber and matrix resin , or be added after [ 0511 ] According to another example, the sheet produced
prepreg is formed . by combining the matrix resin and the reinforced fiber may
[ 0503 ] The reinforced fiber may be any one selected from be the shape of a second sheet including matrix resin and
a group consisting of glass fiber, carbon fiber, graphite fiber, fabric woven by continuous fiber as the reinforced fiber.
US 2021/0351455 A1 Nov. 11 , 2021
20

[ 0512 ] The fabric woven by the continuous fiber may be , fiber, so that strength may be increased in a fiber direction ,
for example, twill fabric or plain fabric of continuous fiber, and excellent structural strength and stiffness may be
or NCF (Non Crimp Fabric ) . attained .
[ 0513 ] The second sheet may include 20 to 70 parts by [ 0522 ] The lamination sheet may include one or more
weight, and particularly 55 to 70 parts by weight of fabric layers of any one sheet selected from a group consisting of
woven by continuous fiber, on the basis of 100 parts by the first sheet, the second sheet, and a combination thereof.
weight of the matrix resin . The basis weight of the fabric For example, each may include 1 to 2000 layers.
may range from 800 g/m² to 1100 g /m². When the content [ 0523 ] Furthermore, the lamination sheet may include the
of the fabric woven by the continuous fiber is less than 20 first and second sheets in the lay -up ratio of 1:10 to 10 : 1 , and
parts by weight, the mechanical strength of the fiber -rein particularly in the lay - up ratio of 1 : 3 to 3 : 1 .
forced plastic composite may be reduced . When the content [ 0524 ] The term “ lay -up ratio ” refers to a ratio of the
is more than 70 parts by weight, the content of the fabric number of first sheets to the number of second sheets . For
woven by the continuous fiber is increased, so that it is example, when the lamination sheet includes two layers of
difficult to realize the lightness of the fiber - reinforced plastic first sheets and three layers of second sheets , the lay -up ratio
composite .
[ 0514 ] The continuous fiber refers to fiber that is not is 2 : 3 , that is , 1 : 1.5 . As such , by setting the number of the
structurally cut and is continuously long , and means fiber layers such that the first and seconds sheets have the lay - up
that is not cut therein and is present in a continuous form ratio of 1:10 to 10 : 1 , the impact resistance of an article to
depending on the entire size of the second sheet. which the fiber - reinforced plastic composite is applied may
be significantly improved , and uniform strength and stiffness
[ 0515 ] Each of single strands of continuous fiber may have may be attained in all directions of the article .
the section diameter ranging from 1 um to 200 um , particu [ 0525 ] The fiber -reinforced plastic composite may have
larly 1 um to 50 um , more particularly 1 um to 30 um , and the heat conductivity of 0.02 W / (mK ) to 0.07 W / (mK ), and
even more particularly 1 um to 20 um . Since the single particularly the heat conductivity of 0.04 W/ (mK) to 0.05
strands of continuous fiber have the section diameter of this W / (mK ). The heat conductivity of the fiber - reinforced plas
range, the strands may be arranged side by side with one ply tic composite may be measured using a heat -conductivity
to thirty plies while having orientation , the impregnation of measuring device that may measure the temperature of the
the matrix resin may be easy in the process of manufacturing opposite side of a heat source under insulation sealing
the second sheet, and the second sheet may be formed to a conditions . As the fiber -reinforced plastic composite has low
proper thickness. heat conductivity and excellent heat insulation properties, it
[ 0516 ] By adjusting the content of the fabric woven by the is possible to attain sufficient heat insulation properties
continuous fiber, the second sheet may be made to the without including a separate insulation member. In this case ,
thickness of about 0.1 mm to 10 mm . In this range , it is in order to attain the heat insulation properties, the thickness
possible to attain the excellent mechanical strength and of the cooling block 300 of 2 mm to 5 mm may be sufficient.
formability and shock absorbing properties. [ 0526 ] A surface of the battery case 10 coming into
[ 0517] The second sheet may be made in the following contact with the battery module may have the heat conduc
method . For example, the matrix resin is put into the tivity of 100 W / (mK ) or more, while a surface opposite to
compounding extruder and then is melted at temperature the surface coming into contact with the battery module may
which is equal to or higher than the melting temperature of have the heat conductivity of 0.05 W/ (mK) or less . To be
the matrix resin . The fabric woven by the continuous fiber is more specific, when the uneven cooling path 310 is formed
conveyed from aa roller into aa mold . The matrix resin which on the top surface of the cooling block 300 and the heat
is melted through the compounding extruder is put into the dissipation plate 200 is coupled between the inner frame 100
mold to impregnate the fabric woven by the continuous fiber. and the cooling block 300 , the heat conductivity from the
[ 0518 ] Subsequently, this may be pressed and cut to a cooling path 310 through the heat dissipation plate 200 may
proper size , thus making the second sheet. To be more be 100 W / (mK ) or more , and the heat conductivity from the
specific, by pressing it using a calendar process, it is possible cooling path 310 through the cooling block 300 may be 0.05
to control the single orientation of the fabric woven by the W / (mK ) or less . Thereby, the battery case 10 may prevent
continuous fiber and manufacture the second sheet having heat from entering the bottom of the cooling block 300
excellent surface properties. without including a separate insulation member under the
[ 0519 ] According to another example , the fiber -reinforced cooling block 300 , and heat absorbed through the heat
plastic composite may include a lamination sheet produced dissipation plate 200 may be effectively removed through
by laminating a plurality of sheets . the cooling path 310. The thermal conductivity may be
[ 0520 ] The lamination sheet may be produced by continu measured using a HFM ( Heat Flow Meter, particularly, EKO
ously laminating a plurality of first sheets, continuously Instruments Trading Co. Ltd, Heat Flow Meter Instrument
laminating a plurality of second sheets, alternately laminat HC - 074 model ) . The fiber -reinforced plastic composite may
ing the first and second sheets, laminating a plurality of first have the specific gravity of 1.4 g/cm3 to 2.2 g / cm ", and
sheets which are continuously laminated and a plurality of
particularly the specific gravity of 1.6 g/cm² to 2.0 g/cmº .
The specific gravity of the fiber -reinforced plastic composite
second sheets which are laminated, and alternately laminat may be measured by the method of ASTM D792 under
ing a plurality of first sheets which are continuously lami isothermal conditions . When the specific gravity of the
nated and a plurality of second sheets which are continu fiber - reinforced plastic composite is in this range , the battery
ously laminated. case 10 may obtain the lightness effect of about 15 wt % or
[ 0521 ] As such , as the fiber - reinforced plastic composite more compared to the existing battery case of the aluminum
includes the lamination sheet , there is little in the bending of material.
US 2021/0351455 A1 Nov. 11 , 2021
21

[ 0527] The fiber - reinforced plastic composite may have long fiber is increased, so that it is difficult to realize the
the falling weight impact strength of 5 J /mm to 20 J /mm , and lightness of the fiber -reinforced plastic composite , and form
particularly the falling weight impact strength of 10 J /mm to ability may be reduced .
15 J /mm . The falling weight impact strength of the fiber [ 0535 ] The long fiber may have the average length of 10
reinforced plastic composite may be measured under the mm to 30 mm , and particularly 10 mm to 20 mm . When the
condition that the room temperature is 23 ° C. and the impact average length of the long fiber is less than 10 mm , manu
energy is 100 J , according to ASTM D3763 . When the facturing cost may be reduced but mechanical properties
falling weight impact strength of the fiber - reinforced plastic may be deteriorated . In contrast, when the average length of
composite is less than 5 J /mm , the battery may be damaged the long fiber is more than 30 mm , it may be difficult for the
due to external shocks. When the falling weight impact fiber to be dispersed in the matrix resin, and formability may
strength is more than 20 J /mm , lightness effect may be be deteriorated .
deteriorated due to the reinforcement of the excessive mate [ 0536 ] Furthermore, the section diameter of the long fiber
rial properties. may range from 5 um to 30 um . When the section diameter
[ 0528 ] The fiber -reinforced plastic composite may have of the long fiber satisfies this range , it is possible to attain the
the tensile strength of 100 MPa to 400 MPa , the tensile mechanical strength and formability of the fiber - reinforced
stiffness of 10 GPa to 30 GPa , and the tensile elongation of plastic composite .
1 % to 4 % . The tensile strength , tensile stiffness, and tensile [ 0537] By adjusting the average length , section diameter,
elongation of the fiber - reinforced plastic composite may be and content of the long fiber, the first sheet may be made to
measured under the condition of 2 mm /min according to the thickness of about 0.1 mm to 10 mm . In this range , it is
ASTM D3039 standard . When the tensile strength, tensile possible to attain the excellent mechanical strength and
stiffness, and elongation of the fiber -reinforced plastic com formability and shock absorbing properties.
posite are out of the minimum range, the structural safety of [ 0538 ] The first sheet may be made in the following
the battery case 10 may be deteriorated by vehicle collision method . First , the matrix resin is put into a compounding
and external load . extruder, and the reinforced fiber pulled out from a plurality
[ 0529 ] The fiber -reinforced plastic composite may have of roving type of yarn bunches is put into aa middle part of
the bending strength of 200 MPa to 500 MPa , the bending the compounding extruder. Subsequently, the reinforced
stiffness of 10 GPa to 30 GPa , and the bending elongation fiber is cut to a predetermined length , and simultaneously the
of 2 % to 4 % . The bending strength , bending stiffness, and cut fiber and the preheated matrix resin are mixed . Subse
bending elongation of the fiber -reinforced plastic composite quently, a strand type of long fiber may be discharged, and
may be measured using an Instron universal tester according then be compressed and formed in the mold to manufacture
to ASTM D - 790 standard under the condition of 5 mm /min the first sheet.
and 16 : 1 span length ratio . When the bending strength, [ 0539 ] The second sheet includes matrix resin and fabric
bending stiffness, and bending elongation of the fiber woven by continuous fiber as the reinforced fiber.
reinforced plastic composite are out of the minimum range , [ 0540 ] The fabric woven by the continuous fiber may be ,
collision safety, structural sagging, and pressure in the path for example, twill fabric or plain fabric of continuous fiber,
may cause a structure to expand and reduce a natural or NCF (Non Crimp Fabric ) .
frequency [ 0541 ] The second sheet may include 20 to 70 parts by
weight, and particularly 55 to 70 parts by weight of fabric
[ 0530 ] The lower protective plate 500 may be made of a woven by continuous fiber, on the basis of 100 parts by
material such as a fiber - reinforced plastic composite, alu weight of the matrix resin . The basis weight of the fabric
minum or steel , and be made of a fiber reinforced plastic
2
may range from 800 g /m² to 1100 g /m2. When the content
( FRP ) composite as an embodiment for realizing lightness. of the fabric woven by the continuous fiber is less than 20
[ 0531 ] According to an example, the fiber reinforced plas parts by weight, the mechanical strength of the fiber -rein
tic (FRP ) composite of the lower protective plate 500 may forced plastic composite may be reduced . When the content
be a lamination sheet including at least one first sheet and at is more than 70 parts by weight, the content of the fabric
least one second sheet. woven by the continuous fiber is increased , so that it is
[ 0532 ] The first sheet includes the matrix resin and the difficult to realize the lightness of the fiber -reinforced plastic
composite.
long fiber as the reinforced fiber. The first sheet is configured [ 0542 ] The continuous fiber refers to fiber that is not
such that the long fiber is dispersed in the matrix resin . structurally cut and is continuously long, and means fiber
[ 0533 ] The first sheet includes long fiber which is superior that is not cut therein and is present in a continuous form
in flowability and formability to the continuous fiber, thus depending on the entire size of the second sheet.
exhibiting excellent processability when the fiber -reinforced [ 0543 ] Each of single strands of continuous fiber mayhave
plastic composite is manufactured . The long fiber means the section diameter ranging from 1 um to 200 um , particu
fiber that is shorter in length than continuous fiber and is cut larly 1 um to 50 um , more particularly 1 um to 30 um , and
to a predetermined length . even more particularly 1 um to 20 um . Since the single
[ 0534 ] The first sheet may include 20 to 70 parts by strands of continuous fiber have the section diameter of this
weight, and particularly 40 to 50 parts by weight of long range , the strands may be arranged side by side with one ply
fiber, on the basis of 100 parts by weight of the matrix resin. to thirty plies while having orientation, the impregnation of
The basis weight of the long fiber may range from 1500 g/m²2 the matrix resin may be easy in the process of manufacturing
to 3500 g /m². When the content of the long fiber is less than the second sheet, and the second sheet may be formed to a
20 parts by weight, it is difficult to expect the mechanical proper thickness.
strength of the fiber -reinforced plastic composite. When the [ 0544 ] By adjusting the content of the fabric woven by the
content is more than 70 parts by weight, the content of the continuous fiber, the second sheet may be made to the
US 2021/0351455 A1 Nov. 11 , 2021
22

thickness of about 0.1 mm to 10 mm . In this range , it is which the fiber - reinforced plastic composite is applied may
possible to attain the excellent mechanical strength and be significantly improved, and uniform strength and stiffness
formability and shock absorbing properties. may be attained in all directions of the article.
[ 0545 ] The second sheet may be made in the following [ 0556 ] Even in this case , the cooling block 300 and the
method . For example, the matrix resin is put into the lower protective plate 500 may be integrated with each
compounding extruder and then is melted at temperature other. In this case , the cooling block 300 and the lower
which is equal to or higher than the melting temperature of protective plate 500 integrated with each other may be made
the matrix resin . The fabric woven by the continuous fiber is of a lamination sheet including at least one first sheet and at
conveyed from aa roller into a mold . The matrix resin which least one second sheet, or be made of at least one first sheet
is melted through the compounding extruder is put into the corresponding to the cooling block 300 and a lamination
mold to impregnate the fabric woven by the continuous fiber. sheet corresponding to the lower protective plate 500 .
[ 0546 ] Subsequently, this may be pressed and cut to a [ 0557] According to another example , the second sheet
proper size , thus making the second sheet . To be more may include at least one 2-1 sheet and at least one 2-2 sheet
specific, by pressing it using a calendar process, it is possible having different fabric orientation angles .
to control the single orientation of the fabric woven by the [ 0558 ] The expression “ fabric has orientation in any one
continuous fiber and manufacture the second sheet having direction in the second sheet ” means that single strands of
excellent surface properties . the continuous fiber in the fabric are arranged in any one
[ 0547] The lamination sheet may be produced by alter direction . Since the fabric is usually manufactured by inter
nately laminating the first and second sheets, laminating a weaving weft and warp arranged in different directions, the
plurality of first sheets which are continuously laminated orientation direction of the fabric is based on only either the
and a plurality of second sheets which are continuously weft or the warp . Furthermore, it should be understood that
laminated, and alternately laminating a plurality of first the expression “ having orientation in any direction ” includes
sheets which are continuously laminated and a plurality of a case where an angle between two certain continuous fibers
second sheets which are continuously laminated . Preferably, is 10 degrees or less , and particularly 5 degrees or less , a
the second sheet is laminated to be disposed on a side to case where the fibers are completely parallel to each other,
which impact is applied , i.e. aa side requiring higher strength . and a case where there is an error range which is difficult to
[ 0548 ] As such , as the fiber - reinforced plastic composite discern when viewed with the naked eyes .
includes the lamination sheet , there is little in the bending of [ 0559 ] To be more specific, the fabric of the 2-1 sheet may
fiber, so that strength may be increased in a reinforced fiber have orientation in a first direction , the fabric of the 2-2 sheet
direction , and excellent structural strength and stiffness may
be attained . may have orientation in a second direction, and the orien
[ 0549 ] FIGS . 52 and 53 are exploded perspective views tation angle between the first direction and the second
showing a fiber - reinforced plastic composite including a direction may have an acute angle, be more than 0 degree
lamination sheet . and less than 90 degrees , particularly range from 10 to 80
[ 0550 ] Referring to FIG . 52 , a fiber -reinforced plastic degrees, more particularly range from 15 to 75 degrees, and
composite 3000 includes a first sheet 3100 and a second even more particularly range from 30 to 60 degrees.
sheet 3200 which are laminated . Although FIG . 52 illustrates [ 0560 ] When at least one 2-1 sheet and at least one 2-2
that the second sheet 3200 includes fabric 3201 woven by sheet having different fabric orientation angles are lami
continuous fiber as reinforced fiber, the fabric 3201 may not nated , strength and stiffness are secured while realizing
be exposed to the surface of the second sheet 3200 . enhanced elongation and energy absorbing performance .
[ 0551 ] Furthermore, although FIG . 52 illustrates that one [ 0561 ] The second sheet may be produced by alternately
first sheet 3100 and one second sheet 3200 are present, the laminating the 2-1 sheet and the 2-2 sheet, laminating a
present disclosure is not limited thereto . A plurality of first plurality of 2-1 sheets which are continuously laminated and
sheets 3100 and a plurality of second sheets 3200 may be a plurality of 2-2 sheets which are continuously laminated ,
laminated . and alternately laminating a plurality of 2-1 sheets which are
[ 0552 ] For example, the lamination sheet may include the continuously laminated and a plurality of 2-2 sheets which
first sheet and the second sheet each having one or more are continuously laminated.
layers. For example, each of the first and second sheets may [ 0562 ] Even in this case , the cooling block 300 and the
include 1 to 2000 layers . lower protective plate 500 may be integrated with each
[ 0553 ] Referring to FIG . 53 , the fiber - reinforced plastic other. In this case , the cooling block 300 and the lower
composite 3000 includes two seconds sheets 3200 , and a protective plate 500 integrated with each other may be made
first sheet 3100 interposed therebetween . However, the of a lamination sheet including at least one first sheet and at
present disclosure is not limited thereto . The second sheet least one second sheet , or be made of at least one first sheet
3200 may be interposed between two first sheets 3100 . corresponding to the cooling block 300 and a lamination
[ 0554 ] Furthermore , the lamination sheet may include the sheet corresponding to the lower protective plate 500 .
first and second sheets in the lay -up ratio of 1:10 to 10 : 1 , and
2 [ 0563 ] FIG . 54 is an exploded perspective view showing
particularly in the lay - up ratio of 1 : 3 to 3 : 1 . a case where a second sheet includes at least one 2-1 sheet
[ 0555 ] The term “ lay - up ratio ” refers to a ratio of the and at least one 2-2 sheet having different fabric orientation
angles.
number of first sheets to the number of second sheets. For
example, when the lamination sheet includes two layers of [ 0564 ] Referring to FIG . 54 , the fiber - reinforced plastic
first sheets and three layers of second sheets, the lay - up ratio composite 3000 includes a first sheet 3100 and a second
is 2 : 3 , that is , 1 : 1.5 . As such, by setting the number of the sheet 3200 which are laminated, and the second sheet 3200
layers such that the first and seconds sheets have the lay - up includes a 2-1 sheet 3210 and a 2-2 sheet 3220 having
ratio of 1:10 to 10 : 1 , the impact resistance of an article to different fabric orientation angles .
US 2021/0351455 A1 Nov. 11 , 2021
23

[ 0565 ] The 2-1 sheet 3210 has the orientation in a first [ 0572 ] After the second sheet was laminated on the first
direction X , the 2-2 sheet 3220 has the orientation in a sheet, they were joined by applying the pressure of 7 ton at
second direction Y , and an angle between the first direction the temperature of 220 ° C.
X and the second direction Y has the orientation angle of Manufacture Example 1-3-2
about 45 degrees.
[ 0566 ] Furthermore, FIG . 54 illustrates that the second [ 0573 ] It was performed in the same manner as Manufac
sheet 3200 includes two 2-1 sheets 3210 and a 2-2 sheet ture Example 1-3-2 , except that the first sheet was laminated
3220 interposed therebetween . However, the present disclo on the second sheet and then they were joined.
sure is not limited thereto . A 2-1 sheet 3210 may be Manufacture Example 1-4
interposed between two 2-2 sheets 3220 .
[ 0567] Although FIG . 54 illustrates that one 2-1 sheet [ 0574 ] A 2 mm -thick first sheet containing 35 parts by
3210 and one 2-2 sheet 3220 are alternately laminated, the weight of glass fiber in the form of long fiber ( average length
present disclosure is not limited thereto . A plurality of 2-1 of 1 inch, section diameter of 20 um ) on the basis of 100
sheets 3210 and a plurality of 2-2 sheets 3220 are continu parts by weight of unsaturated polypropylene resin was
ously laminated , they may be alternately laminated . manufactured .
[ 0575 ] Furthermore, two 0.5 mm - thick second sheets con
MODE FOR INVENTION taining 35 parts by weight of plain fabric of glass fiber
( section diameter of 20 um ) on the basis of 100 parts by
Manufacture Example 1 : Manufacture of weight of unsaturated polypropylene resin was manufac
Fiber -Reinforced Plastic Composite 1 tured .
[ 0576 ] After the two second sheets were laminated on the
Manufacture Example 1-1 first sheet, they were joined by applying the pressure of 7 ton
at the temperature of 220 ° C.
[ 0568 ] A 3 mm - thick first sheet containing 35 parts by
weight of glass fiber in the form of long fiber ( average length Experimental Example 1 : Properties Measurement
of 1 inch , section diameter of 20 um ) on the basis of 100 of Fiber -Reinforced Plastic Composite 1
parts by weight of unsaturated polypropylene resin was [ 0577 ] The specific gravity, falling weight impact
manufactured . strength , tensile properties, and bending properties of the
Manufacture Example 1-2 fiber -reinforced plastic composite manufactured in Manu
facture Example 1-1 to Manufacture Example 1-4 were
[ 0569 ] A 3 mm - thick second sheet containing 35 parts by measured, and the results were shown in Table 1 below.
weight of plain fabric of glass fiber ( section diameter of 20 [ 0578 ] 1 ) Falling Weight Impact Strength (High /Speed
um ) on the basis of 100 parts by weight of unsaturated Puncture Energy, J /mm ): the falling weight impact strength
polypropylene resin was manufactured . was measured under the conditions that room temperature
was 23 ° C. and impact energy was 100 J , according to
Manufacture Example 1-3-1 ASTM D3763 . It was measured by vertically dropping a
falling weight from the top of the manufactured fiber
[ 0570 ] A 2 mm - thick first sheet containing 35 parts by reinforced plastic composite and converting crack genera
weight of glass fiber in the form of long fiber ( average length tion energy from aa crack generation height.
of 1 inch , section diameter of 20 um ) on the basis of 100 [ 0579 ] 2 ) Tensile Properties: They were measured under
parts by weight of unsaturated polypropylene resin was the condition of 2 mm /min , according to ASTM D3039
manufactured standard .
[ 0571 ] Furthermore , a 1 mm - thick second sheet containing [ 0580 ] 3 ) Bending Properties: They were measured using
35 parts by weight of plain fabric of glass fiber ( section the Instron universal tester according to ASTM D - 790
diameter of 20 um ) on the basis of 100 parts by weight of standard under the condition of 5 mm /min and 16 : 1 span
unsaturated polypropylene resin was manufactured . length ratio .
TABLE 1
Manufacture Manufacture Manufacture Manufacture Manufacture
Example1-1 Example1-2 Example1-3-1 Example1-3-2 Example1-4
Specific Gravity 1.65 1.93 1.73 1.76 1.72
Falling weight impact 6.9 10.3 7.4 8.7 7.0
strength ( J /mm )
Tension Strength ( MPa) 152 283 186 186 170
Stiffness (GPa ) 12.0 19.1 14.5 14.5 13.1
Elongation ( % ) 1.64 2.07 1.72 1.72 1.67
Bending Strength ( MPa) 257 439 265 381 341
Stiffness (GPa ) 11.5 22.6 14.5 15.3 19.4
Elongation ( % ) 2.97 2.43 2.41 3.41 2.15
US 2021/0351455 A1 Nov. 11 , 2021
24

[ 0581 ] Referring to Table 1 , it can be seen that the fiber TABLE 2

reinforced plastic composite manufactured in Manufacture Manufacture Manufacture
Example 1-1 is characterized by a high degree of freedom in Example 2-1 Example 2-2
molding, the fiber - reinforced plastic composite manufac
tured in Manufacture Example 1-2 has high stiffness and Fabric lamination pattern A /A/A/A/A /A A / A /B /B /A / A
improved collision performance, the fiber - reinforced plastic Specific gravity 1.77 1.77
Falling weight impact strength 11.4 18.3
composites manufactured in Manufacture Example 1-3-1 ( J /mm )
and Manufacture Example 1-3-2 has a high degree of
freedom in molding and improved collision performance, [ 0588 ] Referring to Table 2 , it can be seen that the falling
and the fiber - reinforced plastic composite manufactured in weight impact strength of Manufacture Example 2-2 is
Manufacture Example 1-4 may have improved cost com improved by about 61 % , compared to that of Manufacture
petitiveness while enhancing collision performance. Example 2-1 .
Manufacture Example 2 : Manufacture of Manufacture Example 3 : Manufacture of Battery
Fiber -Reinforced Plastic Composite 2 Case
Comparative Example 1
Manufacture Example 2-1
[ 0589 ] A lower protective plate of an aluminum material,
[ 0582 ] Six 0.5 mm -thick second sheets containing 35 parts a support part of an aluminum material, and aa heat dissipa
by weight of plain fabric of glass fiber ( section diameter of tion plate of an aluminum material were prepared, lamina
20 um ) on the basis of 100 parts by weight of unsaturated tion was performed in the order of the lower protective plate ,
polypropylene resin was manufactured . the support part, and the heat dissipation plate, an insulating
plate was interposed between the lower protective plate and
[ 0583 ] The second sheets were laminated and joined . After the support part, and then the components were coupled by
a laminate was manufactured such that 2-1 sheets A arranged welding . Although the support part had an uneven cooling
to cause fabric including second sheets to have orientation in path on the top surface thereof, a sidewall extending
the first direction ( 0 degree) have the structure of A / A / A / upwards from the edge portion thereof had no cooling path .
A / A / A , the second sheets were joined by applying the [ 0590 ] The inner and outer frames of the aluminum mate
pressure of 7 ton at the temperature of 220 ° C. rial were welded on the heat dissipation plate. The outer
frame included sidewalls extending upwards from the edge
Manufacture Example 2-2 portion thereof, and front, rear, left, and right sidewalls were
connected to each other to be closed on all sides .
[ 0584 ] Six 0.5 mm - thick second sheets containing 35 parts Embodiment 1
by weight of plain fabric of glass fiber ( section diameter of [ 0591 ] A support part and a lower protective plate were
20 um ) on the basis of 100 parts by weight of unsaturated manufactured by an extrusion -compression molding method
polypropylene resin was manufactured . using the fiber -reinforced plastic composite manufactured in
[ 0585 ] The second sheets were laminated and joined . After Manufacture Example 1-3-2 . In this case , uneven cooling
a laminate was manufactured such that 2-1 sheets A arranged paths were formed on a sidewall extending upwards from an
to cause fabric including second sheets to have orientation in edge portion and the top surface of the support when the
the first direction ( 0 degree ) and 2-2 sheets B arranged to support part was molded.
cause fabric including second sheets to have orientation in [ 0592 ] A heat dissipation plate of an aluminum material
the second direction ( 45 degree ) have the structure of was prepared , lamination was performed in the order of the
A / A / B / B / A / A , the second sheets were joined by applying lower protective plate , the support part, and the heat dissi
the pressure of 7 ton at the temperature of 220 ° C. pation plate , and then the components were attached using
an adhesive.
Experimental Example 2 : Properties Measurement [ 0593 ] An inner frame of a steel material was coupled to
of Fiber - Reinforced Plastic Composite 2 the interior of the sidewall of the support part using the
adhesive . The inner frame was composed of first inner
[ 0586 ] The specific gravity and falling weight impact frames disposed inside the inner frame to extend in a
strength of the fiber - reinforced plastic composite manufac left -and - right direction , second inner frames disposed on
tured in Manufacture Example 2-1 and Manufacture front and rear portions outside the inner frame to extend in
Example 2-2 were measured, and the results were shown in the left- and -right direction , third inner frames disposed
Table 2 below. inside the inner frame to extend in aa front-and -rear direction ,
and fourth inner frames disposed on left and right portions
[ 0587] 1 ) Falling Weight Impact Strength (High / Speed outside the inner frame to extend in the front - and -rear
Puncture Energy, J /mm ): the falling weight impact strength direction .
was measured under the conditions that room temperature [ 0594 ] Furthermore, an outer frame of a steel material was
was 23 ° C. and impact energy was 100 J , according to coupled to an outer surface of the sidewall of the support
ASTM D3763 . It was measured by vertically dropping a part using the adhesive . The left and right sides, front
falling weight from the top of the manufactured fiber portion, and rear portion of the outer frame were not
reinforced plastic composite and converting crack genera connected to each other. The outer frame was composed of
tion energy from a crack generation height. a first side frame, a second side frame, a rear frame, and a
US 2021/0351455 A1 Nov. 11 , 2021
25

front frame. The outer fame included a horizontal rib hori Manufacture Example 4-2
zontally extending inwards to support a part of the bottom of [ 0600 ] This was performed in the same manner as Manu
the support part. facture Example 4-1 , except that the adhesive having the
Experimental Example 3 : Properties Measurement initial curing temperature of 130 ° C. was used .
of Battery Case Manufacture Example 4-3
[ 0595 ] For the battery case manufactured in Embodiment [ 0601 ] This was performed in the same manner as Manu
1 and Comparative Example 1 , a weight, the water -tightness facture Example 4-1 , except that the fiber -reinforced plastic
of a cooling path , and compressive strength ( front, side , and composite was laminated to cover 100 % of the adhesive area
rear) were measured , and the results were shown in Table 3 . and then was molded .
[ 0596 ] 1 ) Water -tightness: in a state where an upper case Manufacture Example 4-4
was bound , the battery case was completely immersed in a
water tank , and it was checked that there was no cooling [ 0602 ] This was performed in the same manner as Manu
leakage after two hours (GB / T 31467.3 standard ). facture Example 4-3 , except that the adhesive having the
[ 0597] 2 ) Compressive strength (kN ): the compressive initial curing temperature of 130 ° C. was used .
strength was measured by a method where a compressive Manufacture Example 4-5
plate was placed on an opposite surface and then aa load was
applied thereto under the condition that one surface was [ 0603 ] The fiber - reinforced plastic composite manufac
fixed ( Chinese GB /T 31467.3 standard ). tured in Manufacture Example 1-1 was put into the mold ,
and was molded at 130 ° C. for 2 minutes such that its
TABLE 3 thickness became 2 mm .
[ 0604 ] The molded fiber - reinforced plastic composite and
Embodiment 1 Comparative Example 1 the metal specimen ( 5 cm wide and 10 cm long ) of alumi
Weight ( kg ) 70 82 num 60 series were attached using the adhesive having the
Water -tightness No leakage No leakage initial curing temperature of 90 ° C. on the basis of 130 ° C.
Compressive Front Standard Satisfied Standard Satisfied and 2 minutes.
Strength (kN ) Side Standard Satisfied Standard Satisfied
Rear Standard Satisfied Standard Satisfied Experimental Example 4 : Properties Measurement
of Integral Molded Product of Metal - Fiber
[ 0598 ] Referring to Table 3 , it can be seen that the battery Reinforced Plastic Composite
case manufactured in Embodiment 1 attained a weight [ 0605 ] For samples manufactured in Manufacture
reduction effect of about 15 % compared to the battery case Example 4-1 to Manufacture Example 4-5 , adhesion , adhe
manufactured in Comparative Example 1 , improved water sive tearing, and adhesive pushing were measured , and the
tightness, and had a similar level of compressive strength . results were shown in Table 4 .
[ 0606 ] 1 ) Adhesion (MPa ) : the fiber - reinforced plastic
Manufacture Example 4 : Manufacture of Integral composite was held by a jig , and the metal specimen was
Molded Product of Metal- Fiber Reinforced Plastic pulled under the condition of 2 mm /min according to ASTM
Composite Using Adhesive D3039 standard , so that tensile strength was measured .
[ 0607] 2 ) Adhesive Tearing: after the fiber - reinforced plas
Manufacture Example 4-1 tic composite and the metal specimen were separated from
each other, an area having no adhesive was visually checked
[ 0599 ] A metal specimen ( 5 cm wide and 10 cm long ) of (a case where adhesive tearing occurred was marked by O ,
aluminum 60 series was loaded in aa lower mold, an adhesive and a case where no adhesive tearing occurred was marked
having the initial curing temperature of 90 ° C. on the basis by X ) .
of 130 ° C. and 2 minutes was laminated on the metal [ 0608 ] 3 ) Adhesive Pushing : before the fiber -reinforced
specimen, and a fiber - reinforced plastic composite manu plastic composite and the metal specimen were separated
factured in Manufacture Example 1-1 was laminated on the from each other, it was visually checked whether the adhe
adhesive to cover 80 % of the adhesive area, and then was sive was out of the metal specimen (a case where adhesive
molded at 130 ° C. for 2 minutes such that the thickness of pushing occurred was marked by O , and a case where no
the fiber - reinforced plastic composite became 2 mm . adhesive pushing occurred was marked by X ) .
TABLE 4
Manufacture Manufacture Manufacture Manufacture Manufacture
Example 4-1 Example 4-2 Example 4-3 Example 4-4 Example 4-5
Adhesion Bad Excellent Bad Good Good
( MPa)
Adhesive X X X X
tearing
Adhesive X X X
pushing
US 2021/0351455 A1 Nov. 11 , 2021
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[ 0609 ] Referring to Table 4 , when the initial curing tem and is very excellent in water - tightness between an interior
perature of the adhesive was in the range of -10 ° C. to + 10 ° and an exterior of the battery case when a battery module is
C. of the curing temperature of the fiber - reinforced plastic mounted thereon .
composite and the fiber -reinforced plastic composite was [ 0613 ] Furthermore , a cooling path is formed to secure
laminated to cover 60 % to 100 % of the adhesive area , it can heat conductivity and realize a reduction in weight, produc
be seen that adhesion between metal and fiber -reinforced tivity can be improved through a convenient coupling struc
plastic composite was excellent. ture between respective components , durability is secured
[ 0610 ] While the present disclosure has been particularly through a robust assembly structure, the stability of the
described with reference to exemplary embodiments shown battery module can be maintained even if external force is
in the drawings, it will be understood by those of ordinary applied due to a multilayered structure , a battery case can be
skill in the art that the exemplary embodiments have been safely and firmly protected , and it is easy to replace some
described for illustrative purposes, and various changes and components when the battery case is damaged .
modifications may be made without departing from the spirit What is claimed is :
and scope of the present disclosure as defined by the 1. A battery case for an electric car, comprising:
appended claims . a support part configured such that a battery module is
seated and supported , and comprising a sidewall
[ Detailed Description of Main Elements ] extending upwards from an edge portion thereof;
10 : battery case 30 : support part
an inner frame coupled to a top surface of the support part
50 : lower mold 60 : upper mold to partition a seat part of the battery module ; and
100 : inner frame an outer ame coupled to an outer surface of the support
110 : first inner frame 112 : first inner protruding frame part.
113 : coupling -member through hole 114 : first inner supporting frame 2. The battery case of claim 1 , wherein the support part
116 : mounting coupling part 120 : second inner frame
122 : second inner upper frame 124 : second inner lower frame comprises a cooling block having on a top surface thereof an
130 : third inner frame 140 : fourth inner frame uneven cooling path .
150 : fastening hole 3. The battery case of claim 2 , wherein the inner frame
200 : heat dissipation plate 240 : unformed part and the outer frame are spaced apart from each other with
250 : fastening hole
300 : cooling block 310 : cooling path the sidewall of the cooling block being interposed therebe
320 : first path partition wall 330 : second path partition wall tween .
340 : spacer 350 : fastening hole 4. The battery case of claim 3 , wherein the cooling block
360 : sidewall 370 : stepped part 9

378 : perforation is made of a fiber -reinforced plastic composite , and

400 : outer frame 410 : first side frame the inner frame and the outer frame are made of a material
420 : second side frame
440 : front frame
430 : rear frame
450 : horizontal rib
different from that of the cooling block .
500 : lower protective plate 540 : protruding support part 5. The battery case of claim 4 , wherein a heat dissipation
550 : fastening hole 600 : adhesive plate is coupled between the inner frame and the cooling
700 : fastening member 710 : bolt block .
720 : nut 730 : coupling member ( SPR ) 6. The battery case of claim 5 , wherein the heat dissipa
1000 : battery case 1100 : support part
1110 : battery- module seat part 1200 : inner frame tion plate and the inner frame are coupled to each other by
1210 : inner external frame 1220 : inner internal frame an adhesive,
1230 : inner frame body 1240 : inner frame coupling body the heat dissipation plate and the cooling block are
1241 : bolt coupling part coupled to each other by the adhesive, and
1300 : outer frame 1310 : outer lower support frame
1311 : outer internal lower support frame 1320 : outer side support frame the cooling block and the outer frame are coupled to each
1321 : outer internal side support frame other by the adhesive .
1600 : adhesive
2100 : upper case 7. The battery case of claim 6 , wherein the inner frame is
2200 : battery module 2300 : lower case coupled to an inside of the sidewall of the cooling block , and
2310 : battery -module seat part 2320 : frame part the outer frame is coupled to an outside of the sidewall of
2321a : cooling path 2321b: space the cooling block .
2321 : body frame 2322 : support frame
2323 : extension frame 2323a : lower- protective -plate
coupling part
8. The battery case of claim 6 , wherein the cooling block
2400 : lower protective plate 2410 : plate part further comprises a fastening hole to be fastened to the inner
2411 : extension coupling part 2411a : lower - case coupling part frame through a fastening hole formed in the heat dissipation
2412 : mounting coupling part 2420 : protruding support part plate .
2500 : coupling member 2510 : bolt 9. The battery case of claim 8 , wherein the cooling block
2520 : nut
3000 : fiber - reinforced plastic composite further comprises a spacer formed around the fastening hole
3100 : first sheet 3200 : second sheet to protrude upwards.
3201 : fabric
3210 : 2-1 sheet 3220 : 2-2 sheet
10. The battery case of claim 8 , wherein the outer frame
comprises a horizontala rib that horizontally extends inwards
to support a part of a bottom surface of the cooling block .
INDUSTRIAL AVAILABILITY
11. The battery case of claim 5 , wherein the heat dissi
pation plate is made of an aluminum material.
[ 0611 ] The present disclosure can be used for a battery 12. The battery case of claim 4 , wherein the fiber
case for an electric car. reinforced plastic composite comprises matrix resin and
[ 0612 ] The battery case for the electric car can reduce the reinforced fiber in the form of long fiber or reinforced fiber
overall weight while satisfying mechanical performance, in the form of fabric woven by continuous fiber.
US 2021/0351455 A1 Nov. 11 , 2021
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13. The battery case of claim 9 , further comprising: 19. The battery case of claim 18 , wherein aa heat dissipa
a lower protective plate coupled to aa bottom of the cooling tion plate made of an aluminum material is coupled between
block . the inner frame and the cooling block .
14. The battery case of claim 13 , wherein the lower 20. The battery case of claim 19 , wherein each of the inner
protective plate is made of a fiber - reinforced plastic com frame and the outer frame is made of a steel material, and
posite . the cooling block is made of a fiber - reinforced plastic
15. The battery case of claim 14 , wherein the lower composite or an aluminum material.
protective plate comprises a protruding support part formed 21. The battery case of claim 19 , wherein the lower
at a position corresponding to the spacer of the cooling block protective plate is made of a fiber - reinforced plastic com
to protrude, and a fastening hole formed at a position posite .
corresponding to the fastening hole of the cooling block, so 22. The battery case of claim 19 , wherein the cooling
9
that the lower protective plate is fastened to the cooling block further comprises a fastening hole to be fastened to the
block by a fastening member. inner frame through a fastening hole formed in the heat
16. The battery case of claim 14 , wherein the cooling dissipation plate.
block and the lower protective plate are integrally formed . 23. The battery case of claim 22 , wherein the cooling
17. A battery case for an electric car, comprising: block further comprises a spacer formed around the fasten
a cooling block configured such that a battery module is ing hole to protrude upwards.
seated and supported ; 24. The battery case of claim 23 , wherein the lower
an inner frame coupled to a top surface of the support part protective plate comprises a protruding support part formed
to partition a seat part of the battery module ; at a position corresponding to the spacer of the cooling block
an outer frame coupled to an outer surface of the support to protrude.
part; and 25. The battery case of claim 24 , wherein the lower
a lower protective plate coupled to a bottom of the support protective plate comprises a fastening hole formed at a
part,
wherein the lower protective plate comprises a sidewall position corresponding to the fastening hole of each of the
formed on an edge portion thereof to extend upwards. cooling block and the heat dissipation plate , so that the lower
18. The battery case of claim 17 , wherein the support part protective plate is fastened to the cooling block and the heat
comprises a cooling block having on a top surface thereof an dissipation plate by a fastening member.
uneven cooling path .