Busbar assembly, battery pack including therein, and vehicle including the battery pack

Abstract

The present invention provides a busbar assembly, a battery pack including the same, and a vehicle including the battery pack. The battery pack is characterized in that it includes: a plurality of battery cells arranged along the length and width directions of the battery pack; and a busbar assembly disposed on one side of the plurality of battery cells, electrically connecting the plurality of battery cells. The busbar assembly includes: a connecting busbar connected in series and in parallel with adjacent battery cells in the length and width directions; and a fuse formed on the connecting busbar, which cuts off the electrical connection of the battery cell experiencing an abnormal condition in the series and parallel connection directions.

Description

Technical Field

[0001] The present invention relates to busbar assemblies, battery packs including such busbar assemblies, and automobiles including such battery packs; more specifically, it relates to busbar assemblies capable of ensuring safety, battery packs including such busbar assemblies, and automobiles including such battery packs. Background Technology

[0002] Besides portable devices, rechargeable batteries, with their convenient application and high energy density, are widely used in electric vehicles (EVs) and hybrid electric vehicles (HEVs) powered by electric motors. These rechargeable batteries not only have the primary advantage of significantly reducing fossil fuel consumption, but also the advantage of producing no byproducts from energy use, making them a highly sought-after environmentally friendly and energy-efficient new energy source.

[0003] Currently, widely used rechargeable batteries include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, and nickel-zinc batteries. The operating voltage of a single rechargeable battery cell, or a single cell, is approximately 2.5V to 4.5V. Therefore, if a higher output voltage is required, multiple battery cells are sometimes connected in series to form a battery pack. Furthermore, depending on the required charge / discharge capacity of the battery pack, multiple battery cells are sometimes connected in parallel to form a battery pack. Therefore, the number of battery cells included in the aforementioned battery packs can be designed in various ways according to the required output voltage or charge / discharge capacity.

[0004] On the other hand, when multiple battery cells are connected in series or parallel to form a battery pack, a battery module including at least one battery cell is usually constructed first, and other components are added using such at least one battery module to form a battery pack or battery rack.

[0005] In the case of conventional battery packs, they are composed of multiple battery cells and a bus assembly for electrically connecting such multiple battery cells. Here, the conventional bus assembly has a fuse that guides the electrical connection of the battery cells by connecting them in series and in parallel, and cuts off the electrical connection of the battery cells in the event of an abnormal condition.

[0006] However, in conventional battery packs, when an abnormal condition occurs, the fuse only cuts off the electrical connection of the battery cell in either the parallel or series direction, thus failing to completely separate the battery cell experiencing an abnormal condition from the other battery cells.

[0007] Therefore, in conventional battery packs, when an abnormal situation occurs, the performance of the entire battery cell is at high risk of deterioration after the electrical connection is severed by the fuse. Furthermore, after the electrical connection is severed by the fuse, the abnormal battery cell can affect adjacent battery cells, potentially causing a chain reaction of explosions and posing a serious safety hazard. Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] Therefore, the object of the present invention is to provide a busbar assembly that disconnects the electrical connection of a battery cell that has malfunctioned in both series and parallel connection directions to ensure safety, a battery pack including the busbar assembly, and a vehicle including the battery pack.

[0010] However, the technical problems to be solved by the present invention are not limited to the above-mentioned problems, and those skilled in the art can clearly understand other problems not mentioned herein from the following description of the invention.

[0011] Methods for solving problems

[0012] To address the aforementioned objective, the present invention provides a battery pack, characterized in that it comprises: a plurality of battery cells arranged along the length and width directions of the battery pack; and a bus assembly disposed on one side of the plurality of battery cells, electrically connecting the plurality of battery cells, the bus assembly comprising: an access bus that is connected in series and in parallel with adjacent battery cells in the length and width directions; and a fuse formed on the access bus that cuts off the electrical connection of the battery cell experiencing an abnormal condition in both the series and parallel connection directions.

[0013] The aforementioned access busbar consists of a single layer of strips with specified length and width.

[0014] The aforementioned fuse element is integrally formed on the aforementioned access busbar.

[0015] The aforementioned access bus includes: a parallel access section formed along either the length direction or the width direction, which connects the battery cells in parallel; a series access section formed along the other direction, which connects the battery cells in series; and an interconnection section that connects the parallel access section and the series access section.

[0016] The aforementioned fuse portion is integrally formed on the aforementioned interconnect portion.

[0017] The aforementioned fused portion can reduce the width of the aforementioned interconnect portion.

[0018] The aforementioned fused portion is formed by recessing the aforementioned interconnect portion to a predetermined depth.

[0019] The aforementioned fused portions are formed at each corner of the edge of the aforementioned interconnect portion.

[0020] The aforementioned fused portion is formed as a hole shape of a predetermined size that can reduce the width of the edge of the aforementioned interconnect portion.

[0021] The aforementioned fuse can sequentially disconnect the electrical connection between the parallel connection section and the series connection section connected to the battery cell that has experienced the aforementioned abnormal condition.

[0022] The aforementioned series connection portion includes: an anode connection portion that extends beyond the aforementioned interconnect portion by a predetermined length; and a cathode connection portion that is disposed on the opposite side of the aforementioned anode connection portion and extends beyond the aforementioned interconnect portion by a predetermined length.

[0023] In the height direction of the aforementioned busbar assembly, the height between the aforementioned anode connection portion and the aforementioned cathode connection portion is the same as the protruding height of the anode on one side of the aforementioned battery cell.

[0024] In the height direction of the busbar assembly, the height of the interconnection portion is higher than the height of the anode connection portion and the cathode connection portion.

[0025] The aforementioned busbar assembly includes a busbar cover that covers the aforementioned access busbar.

[0026] The aforementioned busbar covers are formed as a pair, and the aforementioned access busbar is inserted between the aforementioned pair of busbar covers.

[0027] The aforementioned pair of busbar covers includes: a first cover that covers one side of the aforementioned access busbar; and a second cover that is combined with the first cover and covers the other side of the aforementioned access busbar.

[0028] A busbar hole is formed on the busbar cover, and the busbar hole has an opening space of a specified size that can expose the series connection part.

[0029] The aforementioned busbar hole is formed with an opening space larger than that of the aforementioned series connection portion.

[0030] The aforementioned busbar cover is made of insulating material.

[0031] The aforementioned busbar cover is made of polyimide film.

[0032] The aforementioned access busbars are formed in multiple ways, and the aforementioned busbar cover can cover the aforementioned multiple access busbars.

[0033] The busbar cover has guide holes formed to guide the assembly position of the busbar assembly.

[0034] The strip-shaped structure corresponds to the arrangement of the multiple battery cells.

[0035] Furthermore, the present invention provides an automobile, characterized in that it includes at least one battery pack as described in the above embodiments.

[0036] In addition, the present invention provides a busbar assembly that electrically connects the battery cells of a battery pack. The busbar assembly is characterized in that it includes: an access busbar formed as a strip having a specified length and width, and connected in series and in parallel with the battery cells; and a fuse portion formed on the access busbar, which cuts off the electrical connection of the battery cells that are in abnormal condition in both the series and parallel connection directions.

[0037] The aforementioned access busbar is formed as a single layer.

[0038] The aforementioned fuse section is integrally formed with the aforementioned access busbar.

[0039] The aforementioned access bus includes: a parallel access section formed along either the length or width direction of the aforementioned bus assembly, which connects the aforementioned battery cells in parallel; a series access section formed along the other direction of the length or width direction of the aforementioned bus assembly, which connects the aforementioned battery cells in series; and an interconnection section that connects the aforementioned parallel access section and the aforementioned series access section.

[0040] The aforementioned fuse portion is integrally formed on the aforementioned interconnect portion.

[0041] The aforementioned fused portion can reduce the width of the aforementioned interconnect portion.

[0042] Invention Effects

[0043] According to the various embodiments described above, it is possible to provide a bus assembly that disconnects the electrical connection of a battery cell experiencing an abnormal condition in both series and parallel connection directions to ensure safety, a battery pack including the bus assembly, and a vehicle including the battery pack.

[0044] In addition to the above, other additional effects can be achieved through various embodiments of the present invention. These will be described in detail in the embodiments, or descriptions of effects that are easily conceived by those skilled in the art will be omitted. Attached Figure Description

[0045] The following drawings, which are attached to this specification, illustrate preferred embodiments of the invention and, together with the detailed description of the invention that follows, further explain the technical concept of the invention. Therefore, the invention is not limited to the scope shown in these drawings.

[0046] Figure 1 This is a diagram illustrating a battery pack according to an embodiment of the present invention.

[0047] Figure 2 yes Figure 1 An exploded 3D view of the battery pack.

[0048] Figure 3 It is used for Figure 2 The diagram illustrates the battery cells of the battery pack.

[0049] Figure 4 It is shown Figure 3 A partial cross-sectional view of the internal structure of the battery cell.

[0050] Figure 5 It is shown Figure 3 A partial cross-sectional view of the upper structure of the battery cell.

[0051] Figure 6 It is shown Figure 3 A partial cross-sectional view of the lower structure of the battery cell.

[0052] Figure 7 yes Figure 3 A bottom view of the battery cell.

[0053] Figure 8 It is used for Figure 2 The diagram illustrates the busbar assembly of the battery pack.

[0054] Figure 9 It is used for Figure 8 The diagram illustrates the connection of the busbar assembly to the busbar unit.

[0055] Figure 10 yes Figure 9 A schematic exploded 3D view of the access bus unit.

[0056] Figure 11 Yes Figure 10 An enlarged view illustrating the main components of the access bus unit.

[0057] Figure 12 Yes Figure 9 The diagram illustrates the access bus of the access bus unit.

[0058] Figure 13 yes Figure 12 A top view of the main components of the access busbar.

[0059] Figure 14 It is used for Figure 13 The figure illustrates the fuse section of another embodiment of the access bus.

[0060] Figure 15 yes Figure 13 The figure illustrates the fuse section of another embodiment of the access bus.

[0061] Figure 16 It is used for passing through Figure 12The diagram illustrates the connection of the anode and cathode of the battery cell to the busbar.

[0062] Figure 17 It is used for passing through Figure 12 The diagram illustrates the situation where the battery cells are electrically connected to the busbar.

[0063] Figures 18 to 20 This is a diagram used to illustrate the mechanism by which an electrical connection is cut off by a fuse in one embodiment of the present invention.

[0064] Figure 21 Yes Figure 2 The diagram illustrates the cooling unit of the battery pack.

[0065] Figure 22 yes Figure 21 A cross-sectional view of the cooling unit.

[0066] Figure 23 It is used for Figure 2 The diagram illustrates the side structure unit of the battery pack.

[0067] Figure 24 It is used for Figure 23 The diagram illustrates the mainboard of the side structural unit.

[0068] Figure 25 and Figure 26 It is used for passing through Figure 23 The diagram illustrates the structure that combines the battery unit and the cooling unit through the side structural unit.

[0069] Figure 27 It is used for passing through Figure 23 The diagram illustrates the configuration relationship between the battery cell and the cooling cell, which are implemented through the side structural unit.

[0070] Figure 28 It shows that Figure 23 A diagram of the bottom surface of the side structure unit when it is integrated into the battery unit.

[0071] Figure 29 yes Figure 28 An enlarged bottom view of the main part of the side structural unit.

[0072] Figures 30 to 32 It is used to transmit to Figure 2 The diagram illustrates the process of injecting filler material into a battery pack to form a housing structure.

[0073] Figure 33 This is a diagram illustrating a car according to an embodiment of the present invention. Detailed Implementation

[0074] The invention will be explained more clearly by referring to the accompanying drawings, which detail preferred embodiments of the invention. The embodiments described herein are illustrative and are intended to aid in understanding the invention; the invention can be implemented in various forms and modifications different from those described herein. Furthermore, to aid in understanding the invention, the drawings are not shown to actual scale, but rather as enlarged representations of some of the constituent elements.

[0075] Figure 1 This is a diagram used to illustrate a battery pack according to an embodiment of the present invention. Figure 2 yes Figure 1 An exploded 3D view of the battery pack.

[0076] Reference Figure 1 and Figure 2 The battery pack P is installed in electric vehicles or hybrid vehicles as a power source. The battery pack P in such electric vehicles will be described in more detail below with reference to the accompanying drawings.

[0077] The aforementioned battery pack P includes multiple battery cells 100 and bus assembly 200.

[0078] The aforementioned battery cells 100 are arranged along the length direction (Y-axis direction) and width direction (X-axis direction) of the aforementioned battery pack P. As an example, the aforementioned battery cells 100 are arranged in a roughly matrix shape.

[0079] These multiple battery units 100 can be configured as cylindrical secondary batteries, pouch-type secondary batteries, or square secondary batteries. In this embodiment, the multiple battery units 100 will be described as cylindrical secondary batteries.

[0080] The following describes each battery cell 100 in more detail with reference to the accompanying drawings.

[0081] Figure 3 Yes Figure 2 The diagram illustrates the battery cells of the battery pack. Figure 4 It is shown Figure 3 A partial cross-sectional view of the internal structure of the battery cell. Figure 5 It is shown Figure 3 A partial cross-sectional view of the upper structure of the battery cell. Figure 6 It is shown Figure 3 A partial cross-sectional view of the lower structure of the battery cell. Figure 7 yes Figure 3 A bottom view of the battery cell.

[0082] Reference Figures 3 to 7The battery unit 100 includes an electrode assembly 10, a battery casing 20, a cover plate 30, and a first electrode terminal 40. In addition to the above-mentioned components, the battery unit 100 also includes an insulating pad 50 and / or an upper current collector plate 60 and / or an insulating plate 70 and / or a lower current collector plate 80 and / or a sealing pad 90.

[0083] The electrode assembly 10 includes a first electrode plate having a first polarity, a second electrode plate having a second polarity, and a separation membrane between the first electrode plate and the second electrode plate. The first electrode plate is an anode plate or a cathode plate, and the second electrode plate is equivalent to an electrode plate having a polarity opposite to that of the first electrode plate.

[0084] The electrode assembly 10 described above, for example, has a jelly-roll shape. That is, the electrode assembly 10 is manufactured by winding a laminate formed by sequentially stacking a first electrode plate, a separation membrane, and a second electrode plate at least once, with a winding center C as the reference. In this case, the outer peripheral surface of the electrode assembly 10 has a separation membrane for achieving insulation between it and the battery casing 20.

[0085] The aforementioned first electrode plate includes a first electrode current collector and a first electrode active material coated on one or both sides of the first electrode current collector. An uncoated portion without the first electrode active material is present on one end of the first electrode current collector in the width direction (parallel to the Z-axis). This uncoated portion serves as a first electrode tab. The first electrode tab 11 is located at the upper part of the electrode assembly 10 housed within the battery casing 20 in the height direction (parallel to the Z-axis).

[0086] The second electrode plate includes a second electrode current collector and a second electrode active material coated on one or both sides of the second electrode current collector. An uncoated portion without the second electrode active material exists at the other end of the second electrode current collector in the width direction (parallel to the Z-axis). This uncoated portion serves as a second electrode tab 12. The second electrode tab 12 is located at the lower part of the electrode assembly 10 housed within the battery casing 20 in the height direction (parallel to the Z-axis).

[0087] The battery casing 20, a cylindrical housing with an opening at the bottom, is made of a conductive metal. The sides and top surface of the battery casing 20 are integrally formed. The top surface of the battery casing 20 is generally flat. The battery casing 20 is housed within the electrode assembly 10 through the opening at the bottom, and also houses the electrolyte.

[0088] The battery casing 20 is electrically connected to the second electrode tab 12 of the electrode assembly 10. Therefore, the battery casing 20 has the same polarity as the second electrode tab 12.

[0089] The battery casing 20 has a rolled edge portion 21 and a pressing portion 22 formed at its lower end. The rolled edge portion 21 is formed at the lower part of the electrode assembly 10. The rolled edge portion 21 is formed by pressing the periphery of the outer peripheral surface of the battery casing 20 inward. The rolled edge portion 21 prevents the electrode assembly 10, which has a size corresponding to the width of the battery casing 20, from detaching through the opening formed at the lower end of the battery casing 20, and serves as a support for mounting the cover plate 30.

[0090] The aforementioned crimping portion 22 is formed at the lower part of the rolled edge portion 21. The aforementioned crimping portion 22 has a shape that extends and bends to surround the outer peripheral surface of the cover plate 30 disposed below the rolled edge portion 21 and a portion of the lower surface of the cover plate 30.

[0091] The cover plate 30 is a component made of a conductive metal and covers the opening formed at the lower end of the battery case 20. That is, the cover plate 30 constitutes the lower surface of the battery cell 100. The cover plate 30 is mounted on the rolled edge 21 formed on the battery case 20 and is fixed by the crimping part 22. An airtight gasket 90 for ensuring the sealing of the battery case 20 is located between the cover plate 30 and the crimping part 22 of the battery case 20.

[0092] The cover plate 30 also includes an exhaust section 31 to prevent an increase in internal pressure caused by gas generated inside the battery case 20. The exhaust section 31 corresponds to a region in the cover plate 30 that is thinner than the surrounding area. The exhaust section 31 is structurally weaker than the surrounding area. Therefore, when an abnormality occurs in the battery cell 100 causing the internal pressure to rise above a certain level, the exhaust section 31 is broken, releasing the gas generated inside the battery case 20.

[0093] In one embodiment of the present invention, the battery cell 100 has a structure in which an anode terminal and a cathode terminal are formed at the upper part, thereby the upper structure is more complex than the lower structure. Therefore, in order to smoothly discharge the gas generated inside the battery case 20, an exhaust portion 31 is formed on the cover plate 30 constituting the lower surface of the battery cell 100.

[0094] The exhaust portion 31 is formed continuously in a circular pattern on the cover plate 30. However, it is not limited to this; the exhaust portion 31 may also be formed discontinuously in a circular pattern on the cover plate 30, or it may be formed in a straight line or other shapes.

[0095] The first electrode terminal 40 is made of a conductive metal and is electrically connected to the first electrode tab 11 of the electrode assembly 10 via the upper surface of the battery casing 20. Therefore, the first electrode terminal 40 has a first polarity. The first electrode terminal 40 is electrically insulated from the battery casing 20, which has a second polarity.

[0096] The first electrode terminal 40 includes an exposed terminal portion 41 and an inserted terminal portion 42. The exposed terminal portion 41 protrudes to the outside of the battery case 20. The exposed terminal portion 41 is located at the center of the upper surface of the battery case 20. The inserted terminal portion 42 penetrates the center of the upper surface of the battery case 20 and is electrically connected to the first electrode tab 11. The inserted terminal portion 42 is riveted to the inner side of the battery case 20.

[0097] The upper surface of the aforementioned battery casing 20 The aforementioned first electrode terminals 40 have opposite polarities but face the same direction. Furthermore, a stepped portion is formed between the first electrode terminals 40 and the upper surface of the battery casing 20. Specifically, when the entire upper surface of the battery casing 20 has a flat shape or a shape that protrudes upwards from its center, the exposed terminal portion 41 of the first electrode terminal 40 protrudes upwards more than the upper surface of the battery casing 20. Conversely, when the upper surface of the battery casing 20 has a shape that is recessed downwards from its center, i.e., towards the electrode assembly 10, the upper surface of the battery casing 20 protrudes upwards more than the exposed terminal portion 41 of the first electrode terminal 40.

[0098] The aforementioned insulating pad 50 is positioned between the battery casing 20 and the first electrode terminal 40 to prevent the battery casing 20 and the first electrode terminal 40, which have opposite polarities, from contacting each other. Thus, the upper surface of the battery casing 20, which has a generally flat shape, is used as the second electrode terminal of the battery cell 100.

[0099] The insulating pad 50 includes an exposed portion 51 and an inserted portion 52. The exposed portion 51 is located between the exposed terminal portion 41 of the first electrode terminal 40 and the battery casing 20. The inserted portion 52 is located between the inserted terminal portion 42 of the first electrode terminal 40 and the battery casing 20. The insulating pad 50 is, for example, made of an insulating resin material.

[0100] When the insulating pad 50 is made of resin, it is bonded to the battery casing 20 and the first electrode terminal 40 by heat fusion. In this case, the sealing performance at the interface between the insulating pad 50 and the first electrode terminal 40, and at the interface between the insulating pad 50 and the battery casing 20, is enhanced.

[0101] The entire area on the upper surface of the battery casing 20, excluding the area occupied by the first electrode terminal 40 and the insulating pad 50, corresponds to the second electrode terminal 20a having the opposite polarity to the first electrode terminal 40.

[0102] In one embodiment of the present invention, the battery cell 100 has a first electrode terminal 40 having a first polarity and a second electrode terminal 20a having a second polarity, which is electrically insulated from the first electrode terminal 40. That is, in one embodiment of the battery cell 100, the pair of electrode terminals 40 and 20a are located in the same direction. Therefore, when multiple battery cells 100 are electrically connected, electrical connection components such as the bus assembly 200 can be arranged only on one side of the battery cell 100. This simplifies the battery pack P structure and increases energy density.

[0103] The bus assembly 200, which is electrically connected to the aforementioned plurality of battery cells 100, will now be described in more detail.

[0104] Re-reference Figure 2 The aforementioned busbar assembly 200 is located on one side of the aforementioned battery unit 100, specifically on the upper side (+Z axis direction) of the aforementioned battery unit 100, and electrically connects the aforementioned plurality of battery units 100. The electrical connection of the aforementioned busbar assembly 200 is a parallel connection and / or a series connection. In this embodiment, the electrical connection of the aforementioned busbar assembly 200 is a parallel connection and a series connection.

[0105] Such a bus assembly 200 and the first electrode terminals (40) of the plurality of battery cells 100 having a first polarity, refer to Figure 3 ) and a battery casing with a second polarity (20, see reference) Figure 3 Electrical connection is achieved through connector terminals 280, 290, etc., to external charging / discharging cables, etc. Here, the first polarity is the anode, and the second polarity is the cathode.

[0106] In this embodiment, the description will be limited to the first electrode terminal 40 being the anode and the second electrode terminal 20a being the cathode.

[0107] The structure of the busbar assembly 200 described above will now be explained in more detail.

[0108] Figure 8 It is used for Figure 2 The diagram illustrates the busbar assembly of the battery pack.

[0109] Reference Figure 8 and the above Figure 2 The busbar assembly 200 mentioned above includes a main busbar unit 210.

[0110] The aforementioned main busbar units 210 are formed in multiple units and are electrically connected to the outermost battery unit 100 disposed along the length direction (Y-axis direction) of the battery pack P. These main busbar units 210 are electrically connected to the connector terminals 280 and 290 described later.

[0111] Figure 9 It is used for Figure 8 The diagram illustrates the connection of the busbar assembly to the busbar unit. Figure 10 yes Figure 9 A schematic exploded 3D view of the access bus unit. Figure 11 It is used for Figure 10 An enlarged view illustrating the main components of the access bus unit. Figure 12 It is used for Figure 9 The diagram illustrates the access bus of the access bus unit. Figure 13 yes Figure 12 A top view of the main components of the access busbar.

[0112] Reference Figures 9 to 13 and the above Figure 2 The bus assembly 200 mentioned above includes a bus access unit 230.

[0113] The aforementioned access bus unit 230 is arranged between the aforementioned main bus units 210 along the length direction (Y-axis direction) of the aforementioned battery pack P, and is electrically connected to the aforementioned plurality of battery units 100, and can cover the aforementioned plurality of battery units 100.

[0114] The aforementioned access bus unit 230 is formed as a single component or multiple components capable of completely covering all of the aforementioned battery units 100. Hereinafter, in this embodiment, the access bus unit 230 will be described in multiple forms.

[0115] The aforementioned multiple access bus units 230 each include a bus cover 240 and an access bus 250.

[0116] The aforementioned bus cover 240 covers the access bus 250, which will be described later. This bus cover 240 covers the upper side of the plurality of battery cells 100 and is formed in a generally flat plate shape. The shape and size of the bus cover 240 can be varied depending on the number or capacity of the battery cells 100 required in the battery pack P.

[0117] The busbar cover 240 is made of an insulating material. As an example, the busbar cover 240 is made of polyimide film (Pifilm). However, it is not limited to this, and the busbar cover 240 can also be formed by other different insulating components made of insulating materials.

[0118] The aforementioned busbar covers 240 are configured as a pair and joined together, having corresponding shapes and sizes in the vertical direction (Z-axis direction) of the battery pack P. Here, the access busbar 250, described later, is a single layer and is inserted between the pair of busbar covers 240.

[0119] Specifically, the aforementioned pair of busbar covers 240 includes a first cover 241 and a second cover 242.

[0120] The first cover 241 covers one side of the access bus 250 described later. Specifically, the first cover 241 covers the upper side of the access bus 250 described later. More specifically, the first cover 241 covers the upper sides of multiple access buses 250 together.

[0121] The second cover 242 covers the other side of the access bus 250 (described later). Specifically, the second cover 242 covers the lower side of the access bus 250. More specifically, the second cover 242 covers the lower sides of multiple access buses 250 together. This second cover 242 is combined with the first cover 241. Through the combination of the first cover 241 and the second cover 242, the multiple access buses 250 are arranged between the first cover 241 and the second cover 242, thereby preventing short circuits and ensuring safety.

[0122] The aforementioned busbar cover 240 has busbar holes 243, 244 and guide holes 246 formed on it.

[0123] The aforementioned busbar holes 243 and 244 have openings of a predetermined size that expose the series connection portion 253 of the access bus 250, which will be described later. These busbar holes 243 and 244 improve the workability of electrical connections, such as welding processes, between the series connection portion 253 of the access bus 250 and the battery cell 100, and improve the injection efficiency of the filler material 500, which will be described later.

[0124] The busbar holes 243 and 244 are formed with a larger opening space than the series connection portion 253, so as to improve the workability of the electrical connection and the injection efficiency of the filling material 500.

[0125] Multiple such busbar holes 243 and 244 are formed.

[0126] The aforementioned multiple busbar holes 243 and 244 include anode busbar hole 243 and cathode busbar hole 244.

[0127] The aforementioned anode busbar holes 243 have openings of a predetermined size and are formed in multiple manner. The anode connection portion 254, described later, is exposed on these anode busbar holes 243. Here, the anode busbar holes 243 are formed with openings larger than the anode connection portion 254 to improve process workability and the injection efficiency of the filling material 500, described later.

[0128] The aforementioned anode busbar hole 243 more effectively guides the anode connection portion 254 (described later) to the anode of the battery cell 100, i.e., the first electrode terminal (40, see reference). Figure 3Electrical connection between ).

[0129] Meanwhile, the injection efficiency of the filler material 500 (described later) can be significantly improved through the opening space of the anode busbar hole 243. Specifically, through the opening space of the anode busbar hole 243, the filler material 500 composed of the potting resin 500 (described later) can be injected more directly from the upper side of the battery pack P into the lower direction, i.e., the vertical direction (Z-axis direction), thereby significantly improving the injection efficiency between the battery cells 100.

[0130] The aforementioned cathode busbar holes 244 are arranged opposite to the aforementioned anode busbar holes 243, and each has an opening space of a predetermined size, similar to that of the aforementioned anode busbar holes 243, and is formed in multiple such configurations. Here, the aforementioned cathode busbar holes 244 are formed to have an opening space larger than that of the cathode connection portion 256, which will be described later, in order to improve process workability and the injection efficiency of the filling material 500.

[0131] The aforementioned cathode busbar hole 244 can more effectively guide the cathode connection portion 256 (described later) and the cathode, i.e., the second electrode terminal (20a, see reference) of the battery cell 100. Figure 3 Electrical connection between ).

[0132] Meanwhile, injecting the filler material 500 (described later) through the opening space of the cathode bus hole 244 can significantly improve the injection efficiency of the filler material 500. Specifically, through the opening space of the cathode bus hole 244, the filler material 500 composed of the potting resin 500 (described later) can be injected more directly from the upper side of the battery pack P into the lower direction, i.e., the vertical direction (Z-axis direction), thereby significantly improving the injection efficiency between the battery cells 100.

[0133] The guide hole 246 guides the assembly position of the busbar assembly 200. Specifically, the guide hole 246 fixes the access busbar unit 230 to the side structure unit 400 to guide the fixed position arrangement of the access busbar unit 230.

[0134] The aforementioned guide holes 246 are formed in multiple ways. The busbar guide protrusion 416 of the side structural unit 400, described later, is inserted into the aforementioned multiple guide holes 246.

[0135] The aforementioned access bus 250 is connected in series and in parallel with adjacent battery cells 100 in the length direction (Y-axis direction) and width direction (X-axis direction). Multiple such access buses are formed to connect multiple battery cells 100.

[0136] The aforementioned access bus 250 is formed as a strip with a specified length and width, and is formed as a single layer. Here, the strip is formed in accordance with the arrangement structure of the plurality of battery cells 100. As an example, the strip is formed as a cross-shaped structure, a diagonal structure, or a zigzag shape, depending on the arrangement structure of the battery cells 100.

[0137] The aforementioned access bus 250 is located on the upper side of the aforementioned bus cover 240 or inserted into a pair of bus cover 240. In this embodiment, as described above, it will be limited to being inserted into the aforementioned pair of bus cover 250 for explanation.

[0138] Multiple access buses 250 are formed. These multiple access buses 250 are inserted into the bus cover 240 and are arranged at a predetermined distance apart in the length direction (Y-axis direction) of the battery pack P.

[0139] The aforementioned multiple access buses 250 include parallel access sections 252, series access sections 253, and interconnection sections 257.

[0140] The parallel connection section 252 is configured to connect the battery cells 100 in parallel and is formed along either the length direction (Y-axis direction) or the width direction (X-axis direction) of the battery pack P. Specifically, the parallel connection section 252 is formed along either the length direction (Y-axis direction) or the width direction (X-axis direction) of the bus assembly 200. Hereinafter, in this embodiment, the parallel connection section 252 will be limited to being formed along the width direction of the battery pack P, i.e., the width direction (X-axis direction) of the bus assembly 200, for explanation.

[0141] The parallel connection portion 252 is inserted into the bus cover 240 and is formed to a predetermined length along the width direction (X-axis direction) of the battery pack P. This parallel connection portion 252 is formed in a shape corresponding to the arrangement structure of the battery cells 100 in the width direction (X-axis direction) of the battery pack P to improve the electrical connection efficiency with the battery cells 100. Therefore, in this embodiment, the parallel connection portion 252 is arranged in a zigzag shape in the width direction (X-axis direction) of the battery pack P.

[0142] The parallel connection portion 252 described above is made of a conductive material. As an example, the parallel connection portion 252 is made of aluminum or copper, which are metals. However, it is not limited to this, and the parallel connection portion 252 may also be made of other different materials that achieve the above-mentioned electrical connection.

[0143] The series connection portion 253 connects the battery cells 100 in series and is formed along the other direction of the battery pack P, namely the length direction (Y-axis direction) and the width direction (X-axis direction). Specifically, the series connection portion 253 is formed along the other direction of the bus assembly 200, namely the length direction (Y-axis direction) and the width direction (X-axis direction). Hereinafter, in this embodiment, the series connection portion 253 will be defined as being formed along the length direction of the battery pack P, namely the length direction (Y-axis direction) of the bus assembly 200.

[0144] The aforementioned series connection portion 253 includes an anode connection portion 254 and a cathode connection portion 256.

[0145] The aforementioned anode connection portion 254 extends from the interconnect portion 257 (described later) by a predetermined length and is disposed within the aforementioned anode busbar hole 242. This anode connection portion 254 is connected to the anode (40, see reference) of the aforementioned battery cell 100. Figure 3 Electrical connection. The above-mentioned electrical connection is performed by welding processes such as laser welding or ultrasonic welding, which are used for electrical connection.

[0146] The connection between the anode connection portion 254 and the anode 40 of the battery cell 100 is performed in the opening space of the anode bus hole 242. Therefore, when the connection is made, the welding process and other processes used for the connection are performed directly in the opening space without any additional processes.

[0147] The cathode connection portion 256 is disposed on the opposite side of the anode connection portion 254, and extends from the interconnect portion 257 by a predetermined length and is disposed within the cathode bus hole 244. This cathode connection portion 256 is connected to the cathode (20a, see reference) of the battery cell 100. Figure 3 Electrical connection. The above-mentioned electrical connection is performed by welding processes such as laser welding or ultrasonic welding, which are used for electrical connection.

[0148] The connection between the cathode connection portion 256 and the cathode 20a of the battery unit 100 is performed in the opening space of the cathode bus hole 244. Therefore, during the connection, the welding process and other processes used for the connection are performed directly in the opening space without any additional processes.

[0149] In this way, the anode 40 and cathode 20a of the aforementioned plurality of battery cells 100 are electrically connected to the anode connection portion 254 and cathode connection portion 256 integrated on the single-layer access bus 250 of the aforementioned bus assembly 200.

[0150] The interconnection section 257 connects the parallel access section 252 and the series access section 253. This interconnection section 257, the parallel access section 252, and the series access section 253 are integrally formed to constitute the single-layer access bus 250.

[0151] The aforementioned multiple access bus units 230 each include a fuse section 260.

[0152] The aforementioned fuse 260 is formed on the aforementioned access bus 250, and is capable of cutting off the electrical connection of the battery cell 100 in both series and parallel connection directions when an abnormal condition occurs. Such a fuse 260 can physically separate at least a portion of the aforementioned access bus 250 in the event of an abnormal condition.

[0153] The aforementioned fuse portion 260 is integrally formed on the aforementioned access bus 250. Specifically, the aforementioned fuse portion 260 is integrally formed on the aforementioned interconnect portion 257.

[0154] The aforementioned fusing portion 260 reduces the width of the interconnect portion 257. In regions with relatively high resistance (regions with narrow cross-sectional areas for current flow), relatively more heat is generated, thus the material melts earlier compared to other regions. Therefore, the aforementioned fusing portion 260 is formed by recessing a predetermined depth from the interconnect portion 257. Here, the aforementioned fusing portion 260 is formed at each corner of the edge of the interconnect portion 257.

[0155] In this embodiment, due to the fuse 260, the width W3 of the interconnection portion 257 between the parallel connection portions 252 in the interconnection portion 257 is smaller than the width W1 of the parallel connection portion 252. Furthermore, in this embodiment, due to the fuse 260, the width W4 of the interconnection portion 257 between the series connection portions 253 in the interconnection portion 257 is smaller than the width W2 of the series connection portion 253. That is, the fuse 260 forms a busbar neck portion with a relatively thin thickness in the series connection direction. As a result, in this embodiment, the width of both the series connection portion and the parallel connection portion of the interconnection portion 257 is reduced by the fuse 260.

[0156] Figure 14 It is used for Figure 13 The figure illustrates the fuse section of another embodiment of the access busbar. Figure 15 It is used for Figure 13 The figure illustrates the fuse section of another embodiment of the access bus.

[0157] Reference Figure 14 The fuse portion 263 can also be formed in a square shape, rather than in a shape like... Figure 13This is a circular shape. Also, refer to... Figure 15 The fusible portion 265 can be formed as a hole shape that reduces the edge width of the interconnect portion 257 by a predetermined size inside the interconnect portion 257. Thus, the fusible portions 263 and 265 can have various shapes and configurations that reduce the width of the interconnect portion 257 connecting the parallel connection portion 252 and the series connection portion 253. Furthermore, the fusible portion can be formed as a semi-circular shape, a notch shape, a groove shape, a circular shape, etc., to reduce the width of the interconnect portion 257.

[0158] The electrical connection structure of the battery cell 100 via the access bus 250 will now be described in more detail. Furthermore, the following description... Figures 16 to 20 In order to illustrate the connection structure of the access bus 250 more clearly, the bus cover 240 covering the access bus 250, the cooling unit 300 disposed between the battery units 100 described later, and the side structure unit 400 structure are omitted in the figure.

[0159] Figure 16 It is used for passing through Figure 12 The diagram illustrates the connection of the anode and cathode of the battery cell to the busbar. Figure 17 It is used for passing through Figure 12 The diagram illustrates the case where the battery cells are electrically connected to the busbar. As described above, in Figure 16 and Figure 17 For ease of explanation, the bus cover 240 covering the aforementioned access bus 250, the cooling unit 300 disposed between the battery units 100 described later, and the side structure unit 400 structure are omitted from the figure.

[0160] Reference Figure 16 and Figure 17 When the battery unit 100 and the access bus 250 are electrically connected, the bus assembly (200, see reference) Figure 2 In the height direction (Z-axis direction), the height h1 between the anode connection 254 and the cathode connection 256 is the same as the protrusion height of the anode 40 on one side of the battery cell 100.

[0161] Therefore, when the operator installs the aforementioned access bus 250 on one side of the battery unit 100, specifically on the upper side (+Z axis direction) of the battery unit 100, the aforementioned anode connection portion 254 and the aforementioned cathode connection portion 256 of the access bus 250 are stably and tightly attached to the anode 40 and cathode 20a of the battery unit 100.

[0162] Furthermore, the anode connection portion 254 and the cathode connection portion 256 of the aforementioned busbar 250 can maximize the contact area between the anode 40 and the cathode 20a of the battery cell 100. Therefore, when performing welding processes for electrical connection, etc., poor welding quality can be prevented, and welding accuracy can be significantly improved.

[0163] On the other hand, in the height direction (Z-axis direction) of the busbar assembly 200, the height h2 of the interconnection portion 257 can be higher than the heights of the anode connection portion 254 and the cathode connection portion 256. Therefore, the interconnection portion 257 is configured to be sufficiently separated from the anode 40 and cathode 20a of the battery cell 100, thereby further improving electrical safety.

[0164] Figures 18 to 20 This diagram illustrates the mechanism by which an electrical connection is severed via a fuse element according to an embodiment of the present invention. As described above, in Figures 18 to 20 For ease of explanation, the bus cover 240 covering the aforementioned access bus 250, the cooling unit 300 disposed between the battery units 100, and the side structure unit 400 are omitted from the figure.

[0165] Reference Figures 18 to 20 When an abnormal condition occurs in any of the battery cells 100a in the battery cells 100, the aforementioned fuse part 260 cuts off the electrical connection of the battery cell 100a in the series and parallel connection directions.

[0166] As described above, the fuse section 260 reduces the width of the interconnect section 257 that connects the parallel connection section 252 and the series connection section 253, so that when a high current is applied from the battery cell 100a that is in an abnormal condition to the access bus 250 side, the interconnect section 257 connected to the battery cell 100a that is in an abnormal condition can be melted first.

[0167] The aforementioned fuse portion 260 is formed by reducing the width on both sides of the interconnect portion 257 connected to the aforementioned parallel connection portion 252 and the aforementioned series connection portion 253. Therefore, in the event of the aforementioned abnormal condition, the connection between the aforementioned parallel connection portion 252 and the aforementioned series connection portion 254 can be severed. In other words, the aforementioned fuse portion 260 severs the aforementioned parallel connection and series connection in the region of the interconnect portion 257 connected to the aforementioned parallel connection portion 252 and the aforementioned series connection portion 253. As a result, in the event of the aforementioned abnormal condition, the aforementioned series connection and parallel connection can be severed in the same region through the aforementioned fuse portion 260.

[0168] Thus, in this embodiment, when an abnormal condition occurs, the fuse 260 cuts off the series and parallel connections of the battery cell 100a that is in an abnormal condition, thereby completely separating the battery cell 100a that is in an abnormal condition from the other battery cells 100.

[0169] Therefore, in this embodiment, when the above-mentioned abnormal situation occurs, it is possible to more quickly prevent a chain reaction of disasters to other battery cells 100 around the battery cell 100a where the abnormal situation occurs.

[0170] Meanwhile, in this embodiment, the interconnection portion 257, on which the fuse portion 260 is formed, is disposed at a predetermined distance from the battery cell 100. Therefore, when the fuse portion 260 heats up, the damage to the battery cell 100 can be minimized, thereby maximizing the safety of the battery cell 100.

[0171] On the other hand, the aforementioned fuse 260 can sequentially disconnect the electrical connection between the aforementioned parallel connection portion 252 and the aforementioned series connection portion 253 connected to the battery cell 100a that has experienced the aforementioned abnormal condition.

[0172] When the above-mentioned abnormal conditions occur, such as Figure 19 As illustrated, firstly, the aforementioned fuse portion 260 fuses the connection portion between the aforementioned parallel connection portion 252 and the aforementioned interconnection portion 257, and then... Figure 20 As illustrated, the connection between the series connection portion 253 and the interconnection portion 257 can be melted off. The sequential melting of the parallel connection portion 252 and the series connection portion 253 of the interconnection portion 257 is determined by the current path, first cutting off the connection portion with the series connection portion 253 side, and then cutting off the connection portion with the parallel connection portion 252 side. Simultaneously, depending on the current path, both the series connection portion 253 and the parallel connection portion 252 side can also be cut off simultaneously.

[0173] When such an abnormal situation occurs, the sequential disconnection of the series connection and the parallel connection through the fuse 260 is performed again in the same area, namely the interconnection section 257, so that the heat generated by the fuse 260 can be minimized on the battery cell 100 side.

[0174] Re-reference Figure 2 The bus assembly 200 includes a sensor interconnect board 270 and connector terminals 280 and 290.

[0175] The aforementioned sensor interconnect plate 270 is connected to the aforementioned external sensor line and is disposed at one end (in the Y-axis direction) of the aforementioned battery pack P. The placement of the aforementioned sensor interconnect plate 270 may vary depending on the design, and it may also be disposed at other different locations where it can be connected to the aforementioned external sensor line. Furthermore, multiple aforementioned sensor interconnect plates 270 may be formed depending on the number or capacity of the battery cells 100 in the aforementioned battery pack P.

[0176] The aforementioned sensor interconnect board 270 is formed outside the battery pack 10 for connection to the external sensor lines. The external sensor lines connect the sensor interconnect board 270 and the battery management system (not shown). The battery management system determines the state of charge of the battery cells based on the voltage of the battery cells.

[0177] The aforementioned sensor interconnect 270 includes a thermistor for confirming the temperature state of the battery cell 100. This thermistor can be built into the sensor interconnect 270 or mounted separately externally to the sensor interconnect 270.

[0178] The aforementioned connector terminals 280 and 290 are formed as a pair. This pair of connector terminals 280 and 290 is used to realize the connection with the external charging and discharging line and is composed of high-voltage connector terminals.

[0179] Re-reference Figure 2 The aforementioned battery pack P includes a cooling unit 300.

[0180] The cooling unit 300, which is used to cool the battery unit 100, is disposed on the lower side (-Z-axis direction) of the bus assembly 200 and disposed between the plurality of battery units 100 along the length direction (Y-axis direction) of the battery pack P.

[0181] Multiple cooling units 300 are formed in this manner.

[0182] The aforementioned cooling units 300 are arranged opposite to the aforementioned battery cells 100 in the width direction (X-axis direction) of the aforementioned battery pack P. Here, the aforementioned cooling units 300 are arranged to contact the opposing battery cells 100 in order to improve cooling performance.

[0183] The cooling unit 300 described above will now be explained in more detail.

[0184] Figure 21 It is used for Figure 2 The diagram illustrates the cooling unit of the battery pack. Figure 22 yes Figure 21 A cross-sectional view of the cooling unit.

[0185] Reference Figure 21 , Figure 22 and the above Figure 2 The cooling unit 300 includes a cooling pipe 310, a cooling flow path 350, and a cooling water inlet / outlet 370.

[0186] The cooling pipe 310 is formed to a predetermined length along the length direction (Y-axis direction) of the battery pack P and is disposed between the plurality of battery cells 100. It is provided with a cooling flow path 350 for circulating cooling water as described later.

[0187] The cooling pipe 310 is formed in the width direction (X-axis direction) of the battery pack P in a shape corresponding to the outer surface of the plurality of battery cells 100.

[0188] On the aforementioned cooling pipe 310, a plurality of protrusions 312 and recesses formed in the width direction (X-axis direction) of the battery pack P are alternately arranged along the length direction (Y-axis direction) of the battery pack P.

[0189] The cooling pipe 310 is configured to contact the outside of the plurality of battery cells 100 to further improve the cooling performance of the battery cells 100. The cooling pipe 310 is joined and fixed to the plurality of battery cells 100 by the filling material 500 described later or by a separate joining member.

[0190] The cooling flow path 350 is used to cool the cooling water circulation of the battery unit 100 and is provided in the cooling pipe 310 and connected to the cooling water inlet / outlet 370 described later.

[0191] The aforementioned cooling flow path 350 includes an upper flow path 352, a lower flow path 354, and a connecting flow path 356.

[0192] The aforementioned upper flow path 352 is disposed on the upper side of the cooling pipe 310 close to the busbar assembly 200, and is formed to a predetermined length along the length direction (Y-axis direction) of the cooling pipe 310. This upper flow path 352 is connected to the cooling water supply port 374 of the cooling water inlet / outlet section 370.

[0193] The aforementioned upper flow path 352 is formed in at least one or more forms. In this embodiment, the case where multiple upper flow paths 352 are provided is described to ensure cooling performance.

[0194] The lower flow path 354 is disposed on the lower side (-Z-axis direction) of the cooling pipe 310, spaced apart from at least one upper flow path 352, and is formed to a predetermined length along the length direction (Y-axis direction) of the cooling pipe 310. This lower flow path 354 is connected to the cooling water outlet 376 of the cooling water inlet / outlet section 370.

[0195] The aforementioned lower flow path 354 is formed in at least one or more forms. In this embodiment, the case where multiple lower flow paths 354 are provided is described to ensure cooling performance.

[0196] The aforementioned connecting flow path 356 connects the aforementioned at least one upper flow path, or in this embodiment, a plurality of upper flow paths 352, to the aforementioned at least one lower flow path, or in this embodiment, a plurality of lower flow paths 354.

[0197] The aforementioned connecting flow path 356 is located on the opposite side of the aforementioned cooling water inlet / outlet 370, i.e., at the other end (+Y axis direction) of the aforementioned cooling pipe 310, in order to maximize the cooling flow path 350.

[0198] In this embodiment, during the cooling water circulation in the cooling flow path 350, the cooling water supplied from the cooling water supply port 374 is first supplied to the upper flow path 352, which is located near the busbar assembly 200, and then flows through the connecting flow path 356 and the lower flow path 354 to the cooling water outlet 376.

[0199] Therefore, in this embodiment, cooler cooling water is first supplied to the area near the bus assembly 200, which has a relatively higher temperature distribution within the battery pack P, thereby significantly improving the cooling performance of the battery cell 100.

[0200] The aforementioned cooling water inlet / outlet 370 is connected to the cooling pipe 310 in a manner that communicates with the aforementioned cooling flow path 350 of the cooling pipe 310. Such a cooling water inlet / outlet 370 is exposed to the outside of the side structure unit 400 described later and is connected to the external cooling line.

[0201] The aforementioned cooling water inlet / outlet 370 is provided on one side (-Y-axis direction) along the length (Y-axis direction) of the battery pack P. The aforementioned cooling pipe 310, which is connected to the aforementioned cooling water inlet / outlet 370, is formed to a predetermined length from the aforementioned cooling water inlet / outlet 370 toward the other side (+Y-axis direction) of the battery pack P along the length (Y-axis direction) of the battery pack P.

[0202] The aforementioned cooling water inlet / outlet 370 includes an inlet / outlet body 372, a cooling water supply port 374, and a cooling water outlet 376.

[0203] The aforementioned inlet / outlet body 372 is connected to one end (in the Y-axis direction) of the aforementioned cooling pipe 310. The aforementioned cooling water supply port 374 is provided in the aforementioned inlet / outlet body 372 and is connected to the aforementioned upper flow path 352. This cooling water supply port 374 is connected to the aforementioned external cooling line. The aforementioned cooling water outlet 376 is provided in the aforementioned inlet / outlet body 372 and is connected to the aforementioned lower flow path 374. This cooling water outlet 376 is positioned at a predetermined distance from the aforementioned cooling water supply port 374 and is connected to the aforementioned external cooling line.

[0204] Re-reference Figure 2 The aforementioned battery pack P includes a side structural unit 400.

[0205] The aforementioned side structure unit 400 is made of plastic resin and supports the aforementioned battery unit 100, ensuring the rigidity of the aforementioned battery unit 100 while forming the side appearance of the aforementioned battery pack P.

[0206] The side structural unit 400 described above will now be explained in more detail with reference to the accompanying drawings.

[0207] Figure 23 It is used for Figure 2 The diagram illustrates the side structure unit of the battery pack. Figure 24 It is used for Figure 23 The diagram illustrates the mainboard of the side structural unit.

[0208] Reference Figure 23 and Figure 24 The aforementioned side structural unit 400 is used to support the aforementioned battery unit 100 and ensure the rigidity of the aforementioned battery unit 100, forming the outer side of the aforementioned battery pack P to form the battery pack (P, see reference). Figure 2 The appearance of the housing.

[0209] The aforementioned side structure unit 400 is formed to a predetermined length along the length direction (Y-axis direction) of the aforementioned battery pack P, and houses and supports the aforementioned battery unit 100.

[0210] The aforementioned side structure unit 400 includes a main board 410 and an end board 450.

[0211] The aforementioned motherboard 410 is formed to a predetermined length along the length direction (Y-axis direction) of the battery pack P, and the battery cells 100 are arranged in two rows along the width direction (X-axis direction) of the battery pack P. Multiple such motherboards 410 are formed and arranged at predetermined distances from each other along the width direction (X-axis direction) of the battery pack P.

[0212] Such multiple motherboards 410 ensure the rigidity of the battery unit 100 and the cooling unit 300 while also ensuring the rigidity of the battery pack (P, see reference). Figure 2 The filling material 500 described later occupies a specified space within the filling material 500, thereby reducing the amount of filling material injected. In the case of the filling material 500 composed of silicone resin described later, the cost is relatively high. By reducing the amount of silicone resin injected through the multiple motherboards 410, the cost competitiveness is further ensured when manufacturing the battery pack P.

[0213] The aforementioned multiple motherboards 410 respectively include a first unit storage section 411, a second unit storage section 412, a bottom rib 415, a busbar guide protrusion 416, a cooling unit insertion slot 417, and a guide stop block 418.

[0214] The first unit storage section 411 is disposed at the front (+X-axis direction) of the main board 410 along its length direction (Y-axis direction). This first unit storage section 411 houses the plurality of battery units 100 disposed along the length direction (Y-axis direction) of the battery pack P. Therefore, multiple first unit storage sections 411 are formed at the front (+X-axis direction) of the main board 410.

[0215] The aforementioned plurality of first unit storage portions 411 are each formed in a recessed shape corresponding to the outside of the aforementioned battery unit 100, and surround at least a portion of the outer side surface of the aforementioned battery unit 100.

[0216] The second unit storage section 412 is disposed at the rear (-X-axis direction) of the main board 410 along its length (Y-axis direction). This second unit storage section 412 houses the plurality of battery units 100 disposed along the length (Y-axis direction) of the battery pack P. Therefore, multiple second unit storage sections 412 are provided at the rear (-X-axis direction) of the main board 410.

[0217] The aforementioned plurality of second unit storage portions 412 are each formed in a recessed shape corresponding to the outside of the aforementioned battery unit 100, and surround at least a portion of the outer side surface of the aforementioned battery unit 100.

[0218] The aforementioned plurality of second unit storage sections 412 are arranged intersecting with the aforementioned plurality of first storage sections 411 in the front-back direction (X-axis direction) of the aforementioned main board 410, so as to maximize the storage of the battery unit 100 composed of the aforementioned cylindrical secondary battery.

[0219] The bottom rib 415 is disposed at the bottom of the main board 410 and supports the bottom of the battery unit 100 when the main board 410 houses the battery unit 100.

[0220] The aforementioned bottom rib 415 protrudes further below (in the -Z axis direction) than the bottom of the battery unit 100 when the main board 410 houses the battery unit 100.

[0221] The aforementioned busbar guide protrusion 416, serving as a component for fixing the aforementioned access busbar unit 230 during the assembly of the aforementioned busbar assembly 200, is disposed on the upper surface of the aforementioned main board 410 and is formed as at least one or more. Hereinafter, in this embodiment, the busbar guide protrusion 416 will be described in multiple forms.

[0222] The aforementioned busbar guide protrusion 416 is inserted into the guide hole 246 of the busbar cover 240 during the assembly of the busbar assembly 200, guiding the fixed position of the access busbar unit 230. Since the access busbar unit 230 is inserted into and fixed by the busbar guide protrusion 416, welding processes for electrical connections of the busbar assembly 200 can be performed more stably, further improving the welding quality during these processes.

[0223] The cooling unit insertion slot 417, serving as a component for receiving the end portion of the cooling unit 300, is disposed at the end portion of the main board 410 along its length direction (Y-axis direction). When the end portion of the cooling unit 300 is engaged with the main board 410, it is more stably fixed within the cooling unit insertion slot 417.

[0224] The aforementioned guide stop blocks 418 are provided at a predetermined height on the upper ends of both sides of the main board 410 along its length direction (Y-axis direction). When the side structure unit 400 is assembled, these guide stop blocks 418, together with the end guide stop blocks 458 of the end plate 450, form the edge of the side structure unit 400 by combining with the main board 410 and the end plate 450 (described later).

[0225] The aforementioned end plates 450 are formed as a pair and are disposed on both sides of the outermost contour in the width direction (X-axis direction) of the aforementioned side structure unit 400. The aforementioned pair of end plates 450, together with the main board 410 disposed on the opposite side, house and support the aforementioned battery unit 100.

[0226] The aforementioned pair of end plates 450 have terminal holes 456 and end guide stops 458.

[0227] The aforementioned terminal hole 456 is provided on one side of the end of the aforementioned end plate 450 as a component for accommodating the aforementioned connector terminals 280 and 290.

[0228] The aforementioned end guide stop 458 is formed along the upper edge of the aforementioned end plate 450 and protrudes at the same height as the aforementioned guide stop 418. When the aforementioned side structure unit 400 is assembled, the aforementioned end guide stop 458, together with the guide stop 418 of the aforementioned main board 410, forms the edge of the aforementioned side structure unit 400.

[0229] The following is a more detailed description of the combination structure of the battery unit 100 and the cooling unit 300 through the aforementioned side structure unit 400.

[0230] Figure 25 and Figure 26 It is used for passing through Figure 23 The diagram illustrates the combined structure of the battery unit and cooling unit, which is constructed from the side structural unit.

[0231] Reference Figure 25 and Figure 26 First, in the aforementioned battery cell 100, the cooling pipe 310 of the aforementioned cooling unit 300 is inserted along the aforementioned battery pack (P, reference). Figure 2 The battery cells 100 are arranged in two rows in the width direction (X-axis direction) between the battery cells 100 and the cooling pipe 310 inserted therein. In the front-back direction (X-axis direction) of the battery cells 100, the side structure unit 400 houses the opposing battery cells 100.

[0232] Specifically, in the aforementioned battery pack (P, reference) Figure 2 The battery pack (P, see X-axis direction) is configured with an outermost end plate 450, a battery unit 100, a cooling pipe 310, and a main board 410, arranged in the order of battery unit 100, cooling pipe 310, battery unit 100, and main board 410. Then, the battery pack (P, see X-axis direction) is further configured with these components. Figure 2 In the width direction (X-axis direction) of the side structure unit 400, the outermost end plate 450 located on the opposite side is finally configured and joined together, thereby completing the joining of the side structure unit 400, and thus accommodating the battery unit 100 and the cooling unit 300 within the side structure unit 400.

[0233] Here, when the two ends of the cooling unit 300 are combined with the main board 410 and the end plate 450, they are inserted into the cooling unit insertion slot 417 to prevent interference with the cooling unit 300 and to fix the cooling unit 300 more stably.

[0234] On the other hand, the cooling water inlet / outlet 370 provided at one end of the cooling unit 300 is arranged to protrude outward from the side structure unit 400 in order to connect with external cooling lines, etc.

[0235] The side structure unit 400 of this embodiment, through its combination with the main board 410 and the end plate 450, houses the battery unit 100 and the cooling unit 300 to form the battery pack (P, see reference). Figure 2 The side profile structure of the battery pack P. That is, the side structure unit 400 is used as the housing that forms the appearance of the battery pack P.

[0236] Therefore, the battery pack (P, reference) described in this embodiment Figure 1 The side structure unit 400 eliminates the need for additional housing or outer shell structures, thereby reducing manufacturing costs and shrinking the overall size of the battery pack P to further increase energy density.

[0237] Figure 27 It is used for passing through Figure 23 The diagram illustrates the configuration relationship between the battery cells and cooling units based on the side structural units.

[0238] Reference Figure 27 The distance A between the centers of the battery unit 100 located between the first unit storage portion 411 and the second unit storage portion 412 of the motherboard 410 is a distance set for close contact with the motherboard 410 and can be changed according to the thickness of the motherboard 410.

[0239] Furthermore, the distance B between the centers of adjacent battery cells 100 that are in contact with one side of the cooling pipe 310 is a distance set to form a predetermined angle, such as 60 degrees, between the battery cell 100 and the cooling pipe 310, and changes in conjunction with the distance C described later. The distance C between the centers of battery cells 100 that are arranged opposite each other with the cooling pipe 310 in between is a distance that reflects the thickness of the cooling pipe 310, and is determined in conjunction with the distance B between the centers of adjacent battery cells 100 that are in contact with one side of the cooling pipe 310.

[0240] Distances A to C can be set as the optimal distances to achieve a closer fit between the battery cell 100, the cooling pipe 310, and the side structure unit 400.

[0241] On the other hand, the ends of the first unit storage portion 411 and the second storage portion 412 of the motherboard 410 are formed to be shorter than one side of the battery unit 100 that contacts the cooling pipe 310 in order to prevent interference from the opposing cooling pipe 310. Specifically, the ends of the first unit storage portion 411 and the second storage portion 412 are arranged apart from the cooling pipe 310 with a predetermined gap between them.

[0242] Figure 28 It shows that Figure 23 A diagram of the bottom surface of the side structure unit when it is integrated into the battery unit. Figure 29 yes Figure 28 An enlarged bottom view of the main part of the side structural unit.

[0243] Reference Figure 28 and Figure 29 The bottom rib 415 of the aforementioned side structure unit 400 protrudes further below (in the -Z axis direction) than the bottom of the aforementioned battery unit 100, and is formed in such a way that it does not interfere with the exhaust portion 31 of the aforementioned battery unit 100. As a result, when gas is discharged through the exhaust portion 31 due to overheating of the aforementioned battery unit 100, gas can be discharged more quickly without the interference of the aforementioned bottom rib 415.

[0244] Meanwhile, the bottom rib 415 can cover one side of the bottom of the battery unit 100, thereby further reinforcing the fixation within the side structure unit 400 when housing the battery unit 100.

[0245] Re-reference Figure 2 The aforementioned battery pack P includes filler material 500.

[0246] The aforementioned filling material 500 fills the space between the cooling unit 300 and the plurality of battery cells 100 along the height direction (Z-axis direction) of the battery pack P. On the other hand, in Figure 2 In the diagram, the filling material 500 is represented by a dotted line in the shape of a hexahedron for ease of understanding. The filling material 500 can fill all the spaces between the cooling unit 300 and the plurality of battery units 100.

[0247] Such filling material 500 covers the aforementioned battery pack (P, reference) Figure 2 The upper and lower sides of the battery pack P are together with the side structure unit 400 to form the housing structure of the battery pack P.

[0248] In addition, the filling material 500 fixes the plurality of battery cells 100 more stably and improves the heat dissipation efficiency of the plurality of battery cells 100, thereby further improving the cooling performance of the battery cells 100.

[0249] The aforementioned filler material 500 is composed of potting resin. The potting resin is formed by injecting a thin layer of resin material into the plurality of battery cells 100 and then curing it. Here, the injection of the resin material is performed at a normal temperature of approximately 15 to 25 degrees Celsius to prevent thermal damage to the plurality of battery cells 100.

[0250] Specifically, the filler material 500 is made of silicone resin. However, it is not limited to this; in addition to the silicone resin, the filler material 500 may also be made of other different resin substances that can improve the fixation and thermal dispersion efficiency of the battery cell 100.

[0251] More specifically, the filling material 500 covers the portion of the battery cell 100 that does not contact the cooling pipe 310, thereby guiding the thermal balance of the battery cell 100 and preventing cooling deviations to prevent localized degradation of the battery cell 100. Furthermore, by preventing localized degradation of the battery cell 100, the safety of the battery cell 100 can be significantly improved.

[0252] In addition, when the aforementioned filling material 500 is damaged due to abnormal conditions in at least one particular battery cell 100 among the plurality of battery cells 100, it can play an insulating role in preventing power from being supplied to the adjacent battery cell 100 side.

[0253] Furthermore, the aforementioned filler material 500 includes a material with high specific heat performance. As a result, the aforementioned filler material 500 increases the thermal mass, and in situations such as rapid charging and discharging of the battery cell 100, it can also delay the temperature rise of the battery cell 100, thereby preventing a rapid temperature rise of the battery cell 100.

[0254] In addition, the aforementioned filler material 500 includes glass bubbles. The glass bubbles reduce the specific gravity of the filler material 500, thereby increasing the energy density by relative weight.

[0255] Furthermore, the aforementioned filler material 500 includes a material with high heat resistance. Therefore, when a thermal event such as overheating occurs in at least one of the plurality of battery cells 100, the aforementioned filler material 500 can effectively prevent thermal runaway to the adjacent battery cell side.

[0256] Furthermore, the aforementioned filler material 500 includes a material with high flame-retardant properties. Therefore, the filler material 500 can minimize the risk of fire in the event of a thermal event such as overheating in at least one specific battery cell 100 among the plurality of battery cells 100.

[0257] In addition to the battery unit 100, the aforementioned filling material 500 can also be filled into the bus assembly 200. Specifically, the filling material 500 is filled into the bus assembly 200 in such a way that it covers the upper side of the bus assembly 200.

[0258] Here, the filling material 500 is continuously filled between the bus assembly 200 and the battery unit 100 in the vertical direction (Z-axis direction) of the battery unit 100 without forming an interruption space or a separation space.

[0259] In this way, the filling material 500 of this embodiment is continuously filled into the battery cell 100 and the bus assembly 200 without interruption. Therefore, there is no thermal dispersion deviation in the area between the battery cell 100 and the bus assembly 200, and uniform thermal dispersion is achieved, thereby significantly improving the cooling performance of the battery pack P.

[0260] Simultaneously, the aforementioned filling material 500 can also be filled to portions other than the outer side of the side structural unit 400. Here, the filling material 500 is continuously and uninterruptedly filled to the battery cell 100, the bus assembly 200, and the side structural unit 400. This further improves the cooling performance of the battery pack P.

[0261] The following is a more detailed explanation of the case where a shell structure is formed by injecting the aforementioned filling material 500.

[0262] Figures 30 to 32 It is used for passing through Figure 2 The diagram illustrates the process of injecting filling material into the battery pack to form the housing structure.

[0263] Reference Figures 30 to 32 The aforementioned manufacturers inject and coat a filler material 500 made of the aforementioned silicone resin using a resin injection device I, and form the aforementioned battery pack (P, see reference) using the filler material 500 made of the aforementioned resin material. Figure 2The upper and lower portions of the battery pack housing structure. Specifically, the filling material 500 covers the upper side of the busbar assembly 200 on the upper side (+Z-axis direction) of the battery pack P, and covers the bottom of the battery cell 100 on the lower side (-Z-axis direction) of the battery pack P, filling up to the protrusion height h of the bottom rib 415. Here, the protrusion height h of the bottom rib 415 is designed to take into account the prescribed height of the injection amount of the filling material 500.

[0264] When the filling material 500 is injected and coated using the resin injection device I, an injection guide G is provided at the bottom of the side structure unit 400 to prevent resin from flowing downwards (in the -Z axis direction) during the injection of the filling material 500. The injection guide G is made of polytetrafluoroethylene or the like so that it can be easily removed after the filling material 500 has hardened.

[0265] During the injection and coating process of the filler material 500, the side structure unit 400 and the injection guide G together support the battery unit 100 and the cooling unit 300 to perform the mold function of preventing the resin from flowing out.

[0266] Therefore, in this embodiment, when the filling material 500 is injected and coated through the side structure unit 400, no additional injection guide fixture structure is required in the side direction, thereby significantly improving work efficiency while reducing manufacturing costs.

[0267] In addition, by forming guide stop 418 and end guide stop 458 on the upper surface edge of the side structure unit 400, the injection accuracy of the filler material 500 is improved when the filler material 500 is injected, so that the filler material 500 can be injected more reliably to cover the busbar assembly 200, thereby effectively preventing the filler material 500 from overflowing.

[0268] Here, the components connected to external devices such as the sensor interconnect board 270, connector terminals 280 and 290, and cooling water inlet / outlet 370 are exposed to the outside of the side structure unit 400. Therefore, when the filler material 500 is injected or applied, there will be no interference with the structural components.

[0269] Therefore, in this embodiment, the battery pack (P) is formed by the aforementioned side structure unit 400 and the aforementioned filling material 500. Figure 1 The housing structure (referencing the previous method) simplifies the assembly process of the battery pack P compared to the complex assembly structure formed by multiple plates, significantly reducing manufacturing costs while ensuring cost competitiveness.

[0270] Meanwhile, in this embodiment, the housing structure composed of the aforementioned side structure unit 400 and the aforementioned filling material 500 can reduce the size of the entire battery pack P compared to the conventional housing structure composed of a unit frame structure made of multiple plates, thereby significantly improving the energy density.

[0271] Figure 33 This is a diagram illustrating a car according to an embodiment of the present invention.

[0272] Reference Figure 33 The vehicle V can be an electric vehicle or a hybrid vehicle, and as an energy source, it includes at least one battery pack P as described in the above embodiments.

[0273] In this embodiment, the battery pack P is configured as a compact structure with high energy density. Therefore, when installed in the vehicle V, it is easy to realize the modular structure of multiple battery packs P, and a relatively high degree of installation freedom can be ensured in various internal space shapes of the vehicle V.

[0274] Through the various embodiments described above, it is possible to improve energy density while ensuring the rigidity of the battery pack P and the vehicle V including it.

[0275] Furthermore, according to the various embodiments described above, it is possible to provide a battery pack P and a vehicle V including the battery pack, which improves cost competitiveness and manufacturing efficiency.

[0276] Meanwhile, according to the various embodiments described above, it is possible to provide a battery pack P with improved cooling performance and a vehicle V including the same.

[0277] The preferred embodiments of the present invention have been illustrated and described above. However, the present invention is not limited to the specific embodiments described above. Various modifications can be made by those skilled in the art without departing from the spirit of the invention as claimed in the claims. Such modifications cannot be understood solely from the technical concept or vision of the present invention.

Claims

1. A battery pack, characterized in that, include: Multiple battery cells are arranged along the length and width of the aforementioned battery pack; and A busbar assembly, disposed on one side of the aforementioned battery cells, provides electrical connection to the aforementioned battery cells. The aforementioned busbar assembly includes: The access busbar is connected in series and in parallel with adjacent battery cells in the aforementioned length and width directions; and The fuse, formed on the aforementioned busbar, cuts off the electrical connection of the battery cell experiencing an abnormal condition in both series and parallel connection directions. The aforementioned access busbar consists of a single layer of strips with specified length and width. The aforementioned access bus includes: The parallel connection section is formed along either the length direction or the width direction, and connects the battery cells in parallel. A series connection portion, formed along another direction (either the length direction or the width direction) for connecting the battery cells in series; and An interconnecting section connects the parallel access section and the series access section, wherein the interconnecting section is located at the intersection of the parallel access section and the series access section. The aforementioned fuse portion is integrally formed in the aforementioned interconnect portion, and The aforementioned fused portions are formed at the corners of the edges of the aforementioned interconnect portions, or the aforementioned fused portions are formed as holes of a predetermined size, the predetermined size of which can reduce the width of the edges of the aforementioned interconnect portions.

2. The battery pack according to claim 1, characterized in that, The aforementioned fused portion can reduce the width of the aforementioned interconnect portion.

3. The battery pack according to claim 1, characterized in that, The aforementioned fused portion is formed by recessing the aforementioned interconnect portion to a predetermined depth.

4. The battery pack according to claim 1, characterized in that, The aforementioned fuse can sequentially disconnect the electrical connection between the parallel connection section and the series connection section connected to the battery cell that has experienced the aforementioned abnormal condition.

5. The battery pack according to claim 1, characterized in that, The aforementioned series connection unit includes: The anode connection portion extends a predetermined length beyond the aforementioned interconnection portion; and A cathode connection portion is provided on the opposite side of the anode connection portion and extends beyond the interconnect portion by a predetermined length.

6. The battery pack according to claim 5, characterized in that, In the height direction of the aforementioned busbar assembly, the height between the aforementioned anode connection portion and the aforementioned cathode connection portion is the same as the protruding height of the anode on one side of the aforementioned battery cell.

7. The battery pack according to claim 6, characterized in that, In the height direction of the busbar assembly, the height of the interconnection portion is higher than the height of the anode connection portion and the cathode connection portion.

8. The battery pack according to claim 1, characterized in that, The aforementioned busbar assembly includes a busbar cover that covers the aforementioned access busbar.

9. The battery pack according to claim 8, characterized in that, The aforementioned busbar covers are formed as a pair. The aforementioned access busbar is inserted between the aforementioned pair of busbar covers.

10. The battery pack according to claim 9, characterized in that, The aforementioned pair of busbar covers includes: The first cover, which covers one side of the aforementioned busbar; and The second cover is combined with the first cover and covers the other side of the access bus.

11. The battery pack according to claim 8, characterized in that, A busbar hole is formed on the busbar cover, and the busbar hole has an opening space of a predetermined size that allows the series connection part to be exposed.

12. The battery pack according to claim 11, characterized in that, The aforementioned busbar hole is formed with an opening space larger than that of the aforementioned series connection portion.

13. The battery pack according to claim 8, characterized in that, The aforementioned busbar cover is made of insulating material.

14. The battery pack according to claim 13, characterized in that, The aforementioned busbar cover is made of polyimide film.

15. The battery pack according to claim 8, characterized in that, The aforementioned access busbars are formed in multiple ways. The aforementioned busbar cover can cover multiple of the aforementioned access buses.

16. The battery pack according to claim 8, characterized in that, The busbar cover has guide holes formed to guide the assembly position of the busbar assembly.

17. The battery pack according to claim 1, characterized in that, The strip-shaped structure corresponds to the arrangement of the multiple battery cells.

18. A car, characterized in that, It includes at least one battery pack according to claim 1.

19. A busbar assembly electrically connecting battery cells of a battery pack, characterized in that it comprises: The access busbar is formed as a strip with a specified length and width, and is connected in series and in parallel with the aforementioned battery cells; and The fuse, formed on the aforementioned access bus, cuts off the electrical connection of the battery cell experiencing an abnormal condition in both series and parallel connection directions. The aforementioned access bus includes: The parallel connection section is formed along either the length or width direction of the busbar assembly and connects the battery cells in parallel. A series connection section, formed along either the length or width direction of the aforementioned busbar assembly, connects the aforementioned battery cells in series; and An interconnecting section connects the parallel access section and the series access section, wherein the interconnecting section is located at the intersection of the parallel access section and the series access section. The aforementioned fuse portion is integrally formed in the aforementioned interconnect portion, and The aforementioned fused portions are formed at the corners of the edges of the aforementioned interconnect portions, or the aforementioned fused portions are formed as holes of a predetermined size, the predetermined size of which can reduce the width of the edges of the aforementioned interconnect portions.

20. The busbar assembly according to claim 19, characterized in that, The aforementioned access busbar is formed as a single layer.

21. The busbar assembly according to claim 19, characterized in that, The aforementioned fused portion can reduce the width of the aforementioned interconnect portion.

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