Bus bar assembly and battery pack including the same

Abstract

A bus bar assembly according to an embodiment of the present disclosure includes a bus bar including a main body portion and end portions extending from both ends of the main body portion and defining a through hole, an insulating layer surrounding the main body portion, and a cover plate covering the insulating layer and the end portions and having an integral shape.

Description

Technical Field

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of Korean Patent Application No. 10-2023-0063579 filed in the Korean Intellectual Property Office on May 17, 2023, the disclosure of which is incorporated herein by reference in its entirety.

[0003] The present disclosure relates to a bus bar assembly and a battery pack including the same, and more particularly, to a bus bar assembly that allows easy discharge of carbonized gas and does not require a cap, and a battery pack including the same. Background Art

[0004] In modern society, as portable devices such as mobile phones, laptop computers, camcorders, and digital cameras have been used daily, the development of technology in the field related to the mobile devices as described above has been activated. In addition, rechargeable / dischargeable secondary batteries are used as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (P-HEVs), etc., in an attempt to solve air pollution caused by existing gasoline vehicles using fossil fuels, etc. Therefore, the demand for the development of secondary batteries is growing.

[0005] Currently commercialized secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, lithium secondary batteries, etc. Among them, lithium secondary batteries have attracted attention because they have advantages such as showing almost no memory effect compared to nickel-based secondary batteries and thus being freely charged and discharged, and having a very low self-discharge rate and high energy density.

[0006] Such lithium secondary batteries generally use lithium-based oxides and carbon materials as positive electrode active materials and negative electrode active materials, respectively. The lithium secondary battery includes an electrode assembly, in which a positive electrode plate and a negative electrode plate coated with positive electrode active materials and negative electrode active materials, respectively, are provided, and a separator is interposed between the positive electrode plate and the negative electrode plate, and the external material or battery case seals and contains the electrode assembly together with an electrolyte.

[0007] According to the shape of external materials, generally, lithium secondary batteries can be divided into can-type secondary batteries in which an electrode assembly is incorporated into a metal can and pouch-type batteries in which an electrode assembly is incorporated into a pouch of an aluminum laminate sheet.

[0008] In the case of a secondary battery for a small device, two to three battery cells are provided, but in the case of a secondary battery for a medium and large device such as an automobile, a battery module in which a plurality of battery cells are electrically connected is used. In such a battery module, a plurality of battery cells are connected in series or in parallel to each other to form a cell assembly, thereby increasing capacity and output. In addition, one or more battery modules may be installed together with various control and protection systems such as a BDU (battery disconnect unit), a BMS (battery management system), and a cooling system to form a battery pack.

[0009] In a battery pack configured to aggregate a plurality of battery modules, heat generated from a plurality of battery cells may be accumulated in a narrow space, so that the temperature may rise faster and excessively. In other words, a battery module in which a plurality of battery cells are stacked and a battery pack equipped with these battery modules may obtain high output, but it is not easy to remove heat generated from the battery cells during charging and discharging. When heat dissipation of the battery cells is not properly performed or a thermal runaway phenomenon occurs in the battery cells, the possibility of continuous fire or explosion increases.

[0010] In addition, bus bars connected to the battery modules are provided inside the battery pack.

[0011] Figure 1 It is an exploded perspective view and a connection perspective view of a traditional busbar assembly.

[0012] Reference Figure 1 , a conventional busbar assembly 10 includes a busbar 20, a cover 20C surrounding the busbar 20, a cap CP, and a strip AL for fixing the cap CP. The busbar 20 is a rod-shaped metal member extending in the longitudinal direction. Through holes HH for connecting to the terminal busbars of the battery module may be formed at both ends of the busbar 20. Such a busbar 20 is configured to be responsible for the HV (high voltage) connection in the battery pack. The HV connection refers to a connection used as a power source for supplying electric power, and the busbar 20 is configured to guide the electrical connection of the battery module, and generally includes a metal material having excellent electrical conductivity. For example, the busbar 20 may include a copper (Cu) material.

[0013] The cover 20C may surround the bus bar 20. The cover 20C may include an electrically insulating material, for example, it may include a material such as silicone or epoxy. Since the cover 20C surrounds the bus bar 20 through which a high current flows, the bus bar 20 may be prevented from contacting other electrical devices or conductive members other than the terminal bus bar of the battery module, thereby preventing a short circuit from occurring.

[0014] The fastening member may be inserted into the through hole HH of the bus bar 20 to connect the bus bar 20 to the terminal bus bar of the battery module. Caps CP are attached to both ends of the bus bar 20 for insulation. The caps CP may be, for example, rubber covers. The caps CP may be attached to the cover 20C using a tape AL.

[0015] However, when a flame is generated inside the battery pack, the temperature of the flame is very high, about 1000°C, and the cover 20C surrounding the bus bar 20 melts, or the cap CP and the band AL melt, so that the bus bar 20 may be exposed. If the exposed bus bar 20 contacts another conductive member to cause a short circuit, the internal flame may spread further, and the flame may even spread to the outside of the battery pack. This may eventually lead to the explosion of the battery pack or a vehicle equipped with the battery pack.

[0016] Therefore, there is a need to develop a technology for a bus bar assembly that can maintain electrical insulation properties even if a fire occurs inside a battery pack. Summary of the invention

[0017] Technical issues

[0018] An object of the present invention is to provide a bus bar assembly which can maintain electrical insulation characteristics without melting even when a fire is generated inside the battery pack, and a battery pack including the same.

[0019] However, the technical problems to be solved by the embodiments of the present disclosure are not limited to the above-mentioned problems, and various extensions can be made within the scope of the technical ideas included in the present disclosure.

[0020] Technical Solution

[0021] According to one embodiment of the present disclosure, a bus bar assembly is provided, which includes: a bus bar, the bus bar including a main body and end portions extending from both ends of the main body and defining through holes; an insulating layer, the insulating layer surrounding the main body; and a cover plate, the cover plate covering the insulating layer and the end portions and having an integral shape.

[0022] The cover plate may expose one surface of the insulating layer.

[0023] The shape of the cover plate in a plane may be arranged along the outer contours of the insulating layer and the end portion.

[0024] The shape of the cover plate on the side surface may be arranged along the outer contours of the insulating layer and the end portion.

[0025] The cover plate may include: a top surface; two short side surfaces, the two short side surfaces are arranged in the short side direction of the bus bar; and two long side surfaces, the two long side surfaces are arranged in the long side direction of the bus bar and are formed along the shapes of the insulating layer and the end portion.

[0026] The cover plate may include: a top surface, which is formed along the shape of the insulating layer and the end; two short side surfaces, which are arranged in the short side direction of the busbar; a long side surface, which is arranged in the long side direction of the busbar; and a bottom surface, which faces the top surface and is formed along the shape of the insulating layer.

[0027] The insulating layer may be ceramized at high temperature.

[0028] According to another embodiment of the present disclosure, a bus bar group is provided, comprising: a bus bar assembly; a battery module; a BDU (battery disconnect unit) module for controlling the electrical connection of the battery module; and a BMS (battery management system) module for monitoring and controlling the operation of the battery module, wherein the at least one bus bar assembly is electrically connected to at least one of between the battery modules, between the battery module and the BDU module, between the battery module and the BMS module, and between the BDU module and the BMS module.

[0029] The bus bar group may further include a fastening portion coupled to the through hole of the at least one bus bar assembly, wherein the cover plate covers the fastening portion.

[0030] The battery module includes a first battery module, a second battery module adjacent to the first battery module, a third battery module facing the first battery module, and a fourth battery module adjacent to the third battery module and facing the second battery module, and the at least one bus bar assembly includes: a first bus bar assembly connecting the first battery module and the second battery module; and a second bus bar assembly connecting the third battery module and the fourth battery module and facing the first bus bar; the first bus bar assembly is constructed so that the bottom surface is exposed from the cover plate, and the second bus bar assembly can be constructed so that one side surface is exposed from the cover plate.

[0031] An exposed bottom surface of the first bus bar assembly may face the first and second battery modules, and an exposed one side surface of the second bus bar assembly may face the third and fourth battery modules.

[0032] Beneficial Effects

[0033] The bus bar assembly of the present disclosure includes a cover plate that can replace a cap, thereby improving insulation performance and fire resistance.

[0034] The bus bar assembly of the present disclosure may allow gas generated inside thereof to be easily discharged to the outside when exposed to flame.

[0035] Effects obtainable from the present disclosure are not limited to the above-mentioned effects, and further other effects not mentioned herein will be clearly understood by those skilled in the art from the description of the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is an exploded perspective view and a connection perspective view of a traditional busbar assembly.

[0037] Figure 2 is a top view of a battery pack according to one embodiment.

[0038] Figure 3 It is shown that the Figure 2 A three-dimensional view of a battery module in a battery pack.

[0039] Figure 4 It is shown in Figure 3 A partial three-dimensional view of a battery module with the module frame and end plates removed.

[0040] Figure 5 is a perspective view of a bus bar according to one embodiment.

[0041] Figure 6 is a perspective view of a bus bar provided with an insulating layer according to one embodiment.

[0042] Figure 7 is an exploded perspective view of a bus bar assembly according to one embodiment.

[0043] Figure 8 is a plan view of a bus bar assembly according to one embodiment.

[0044] Fig. 9 is a side view of a bus bar assembly according to one embodiment.

[0045] Fig.10 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0046] Fig.11 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0047] Fig.12 is an exploded perspective view of a bus bar assembly according to one embodiment.

[0048] Fig.13is a plan view of a bus bar assembly according to one embodiment.

[0049] Fig.14 is a side view of a bus bar assembly according to one embodiment.

[0050] Fig.15 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0051] Fig.16 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0052] Fig.17 is a side view of a bus bar assembly connecting battery modules according to one embodiment.

[0053] Fig.18 is a side view of a bus bar assembly connecting battery modules according to one embodiment.

[0054] Fig.19 is a plan view of a bus bar assembly connecting battery modules according to one embodiment. DETAILED DESCRIPTION

[0055] Hereinafter, various embodiments of the present disclosure will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily implement them. The present disclosure can be modified in various different ways and is not limited to the embodiments set forth herein.

[0056] For clarity, descriptions of parts not relevant to the description will be omitted, and the same reference numerals will be used throughout the description to denote the same or similar elements.

[0057] In addition, in the drawings, for the convenience of description, the size and thickness of each element are arbitrarily shown, and the present disclosure is not necessarily limited to those shown in the drawings. In the drawings, for the sake of clarity, the thickness of layers, regions, etc. are exaggerated. In the drawings, for the convenience of description, the thickness of components and regions is magnified.

[0058] In addition, it should be understood that when an element such as a layer, film, region, or plate is referred to as being "on" or "over" another element, it can be directly on the other element, or intervening elements may also be present. Conversely, when an element is referred to as being "directly on" another element, it means that there are no other intervening elements. In addition, a component located "on" or "over" a reference portion means a component located above or below the reference portion, and does not specifically mean a component "on" or "over" facing in the opposite direction of gravity.

[0059] Furthermore, throughout the specification, when a part is referred to as “including” or “comprising” a certain component, it means that the part may further include other components, without excluding other components, unless otherwise specified.

[0060] Furthermore, throughout the specification, when referred to as a “plane”, it means when the target portion is viewed from the upper side, and when referred to as a “cross section”, it means when the target portion is viewed from one side of a cross section cut vertically.

[0061] In addition, throughout the specification, the first direction DR1, the second direction DR2, and the third direction DR3 are used as related concepts. The first direction DR1, the second direction DR2, and the third direction DR3 may perpendicularly intersect each other.

[0062] Throughout the description, the up / down concept is described as being divided along the third direction DR3. Therefore, the "thickness" herein refers to the length measured in the third direction DR3.

[0063] Figure 2 is a top view of a battery pack according to one embodiment.

[0064] Reference Figure 2 , a battery pack 1000 according to one embodiment includes a bus bar assembly 100, a battery pack frame 1100, a battery module 1200, a BDU (battery disconnect unit) module 1300 for controlling electrical connection of the battery module 1200, and a BMS (battery management system) module 1400 for monitoring and controlling the operation of the battery module 1200. At least one bus bar assembly 100 according to the present embodiment is electrically connected between the battery modules 1200, between the battery module 1200 and the BDU module 1300, between the battery module 1200 and the BMS module 1400, and between the BDU module 1300 and the BMS module 1400. Specifically, a plurality of battery modules 1200 may be accommodated in the battery pack frame 1100, and an electrical connection between the battery modules 1200 or an electrical connection between the battery modules 1200 and the BDU module 1300 may be formed by the bus bar assembly 100. That is, the bus bar assembly 100 according to the present embodiment may be responsible for HV (high voltage) connection. Here, the HV connection is a power supply connection for supplying electric power requiring a high voltage, and refers to a connection between battery cells or a connection between battery modules.

[0065] In addition, the BDU module 1300 is a member for controlling the electrical connection of the battery module 1200, and can cut off the power between the power converter and the battery module 1200. When the current exceeds the set range, the BDU module 1300 can cut off the power of the battery pack 1000 to ensure the safety of the battery pack 1000.

[0066] In addition, the LV connecting member 100' according to the present embodiment can be responsible for the electrical connection between the battery module 1200 and the BMS module 1400. The electrical connection here is a LV (low voltage) connection, which means a sensing connection for detecting and controlling the voltage and temperature of the battery module 1200. Specifically, sensors and the like are arranged inside the battery module 1200, and the real-time temperature information or voltage information of the battery module 1200 is transmitted to the BMS module 1400 via the LV connecting member 100'. The real-time operating status of the battery module 1200 can be monitored and controlled by the BMS module 1400. Although not specifically shown, the HV current sensor can be integrated into the BMS module 1400. In this case, the bus bar assembly according to the present embodiment can be responsible for the electrical connection between the battery module 1200 and the BMS module 1400 or between the BDU module 1300 and the BMS module 1400.

[0067] Next, we will refer to Figure 3 and Figure 4 A battery module 1200 according to the present embodiment is described. In this regard, the battery module 1200 described below has one exemplary structure of a battery module including a plurality of battery cells 11 , and various types of battery modules including a plurality of battery cells may be applied.

[0068] Figure 3 It is shown that the Figure 2 A three-dimensional view of a battery module in a battery pack.

[0069] Figure 4 It is shown in Figure 3 A partial three-dimensional view of a battery module with the module frame and end plates removed.

[0070] See also Figure 3 and Figure 4 , the battery module 1200 according to the present embodiment may include a battery cell stack 11A in which a plurality of battery cells 11 are stacked. Figure 4 Such a battery cell stack 11A may be accommodated in a module frame 30 and an end plate 40 .

[0071] The battery cell 11 may be a pouch-type battery cell. Such a pouch-type battery cell may be formed by housing an electrode assembly in a pouch shell made of a laminate sheet including a resin layer and a metal layer, and then fusing the outer periphery of the pouch shell. Such a battery cell 11 may be formed into a rectangular sheet structure. The electrode lead 11L connected to the electrode assembly protrudes to the outside of the pouch shell, wherein the electrode lead 11L of each battery cell 11 may be electrically connected to each other via a lead bus bar 21. On the other hand, at least one electrode lead 11L may be connected to a terminal bus bar 22. As Figure 3As shown, a portion of the terminal bus bar 22 may be exposed to the outside of the battery module 1200. Both the lead bus bar 21 and the terminal bus bar 22 may include a metal material having excellent electrical conductivity.

[0072] The bus bar assembly 100 according to the present embodiment is electrically connected to such a terminal bus bar 22 , thereby enabling the above-mentioned HV connection. That is, the battery module 1200 can be electrically connected to the battery module 1200 , the BDU module 1300 , or the BMS module 1400 via the bus bar assembly 100 connected to the terminal bus bar 22 .

[0073] Next, we will refer to Figures 5 to 11 A bus bar assembly according to an embodiment is described.

[0074] Figure 5 is a perspective view of a bus bar according to one embodiment.

[0075] Reference Figure 5 , bus bar 200 guides battery pack 1000 (see Figure 2 ) within the battery module 1200 (see Figure 2 ) of the electrical connection (ie, HV connection), and may include a metal material having excellent electrical conductivity. As an example, the bus bar 200 may include a copper (Cu) material. The body portion 210 may have a rod shape extending in one direction. Figure 2 , as an example, the bus bar 200 is shown to have a rod shape extending in the first direction DR1.

[0076] The bus bar 200 of one embodiment includes a main body 210 and an end portion 220. The main body 210 may correspond to the central portion of the bus bar 200. The end portion 220 extends from both ends of the main body 210. For example, the end portion 220 may extend in a first direction DR1 and a direction opposite to the first direction DR1 at both ends of the main body 210. In this specification, for convenience, the bus bar 200 is described as including the main body 210 and the end portion 220, but the main body 210 and the end portion 220 have an integral shape.

[0077] A through hole HH is defined in the end portion 220. A fastening member may be inserted into the through hole HH to connect the bus bar 200 to an external electrical device. For example, a bolt may be inserted into the through hole HH of the end portion 220 to connect the battery module 1200 (see FIG. 1 ). Figure 3 ) busbar 20 and terminal busbar 22 (see Figure 3 ).

[0078] Figure 6 is a perspective view of a bus bar provided with an insulating layer according to one embodiment.

[0079] Reference Figure 6 The insulating layer 300 surrounds the main body 210 of the bus bar 200 (see Figure 5 That is, the insulating layer 300 may surround the outer peripheral surface of the bus bar 200 except for the end portion 220 of the bus bar 200. The end portion 220 may be exposed from the insulating layer 300 and electrically connected to the terminal bus bar 22 of the battery module 1200 (see Figure 4 ).

[0080] The insulating layer 300 may include refractory silicon. For example, refractory silicone may be molded onto the main body portion 210 ( Figure 5 ) to form an insulating layer 300. Unlike ordinary silicon materials that are exposed to flames or burn at high temperatures, refractory silicone resins can be ceramicized at high temperatures. Therefore, when exposed to flames, refractory silicon does not burn but undergoes ceramicization, and can maintain insulating properties to the bus bar 200. For example, refractory silicon can be ceramicized at a temperature of 500 degrees Celsius or higher and 1700 degrees Celsius or lower. However, the temperature range in which refractory silicon is ceramicized is not limited thereto.

[0081] Refractory silicone resin may include silicone polymer and silicon dioxide. For example, the silicone polymer applied may be a polysiloxane compound having vinyl as a functional group, and may be used as a base material for refractory silicone materials. For example, the silicon dioxide applied may be fumigated silicon dioxide, which is a reinforcing filler contained in the silicone polymer. With metallic silicon as the main raw material, a high-purity silicon chloride (SiCl4) compound may be obtained by reaction with hydrochloric acid and purification process, which may react with hydrogen and oxygen in a high temperature flame to obtain fumigated silicon dioxide. In addition, refractory silicon may contain platinum Pt as a catalyst.

[0082] When refractory silicon is exposed to flame or high heat, silicon dioxide (SiO2) crosslinks together and the silicone polymer decomposes to form a ceramic material. The insulating layer 300 of one embodiment including refractory silicon does not burn or melt, but can withstand ceramicization and maintain electrical insulation properties even when exposed to flame or placed in a high temperature environment.

[0083] Therefore, even under flame or high temperature, the insulating layer 300 can make the main body 210 (see FIG. Figure 5 ) is insulated, thereby preventing the bus bar 200 from contacting other electrical equipment or conductive components and causing a short circuit.

[0084] Figure 7 is an exploded perspective view of a bus bar assembly according to one embodiment.

[0085] Reference Figure 7, a bus bar assembly 100 of one embodiment may include a bus bar 200, an insulating layer 300 and a cover plate 400. Figure 7 , for convenience of explanation, there is also shown a fastening member BT coupled to the end portion 220 of the bus bar 200. A bolt is shown as an example of the fastening member BT.

[0086] The cap plate 400 of the present disclosure covers the insulating layer 300 and the end portion 220 and has an integral shape.

[0087] The cover plate 400 of the present invention may include mica. The cover plate 400 may be a thermoformed mica plate formed by hot pressing using a high temperature press. The cover plate 400 is thermoformed to match the outer shape of the bus bar 200 and the insulating layer 300 so that it can be provided in an assembled manner without a separate adhesive layer. In addition, compared with soft mica tape or sheet mica, the cover plate 400 of the present disclosure maintains a solid appearance and can physically protect the internal structure.

[0088] The cover plate 400 has excellent fire resistance, heat resistance, high temperature resistance and electrical insulation, and can maintain the insulation of the bus bar assembly 100 without burning under flame or high heat. Therefore, when a flame is generated, the cover plate 400 can cut off the insulating layer 300 from being directly exposed to the flame. In addition, the cover plate 400 can physically protect and isolate the end 220 and the fastening member BT coupled to the end 220. The cover plate 400 can replace the cap CP (see FIG. 1 ) included in the conventional bus bar assembly 10. Figure 1 ) and strip AL.

[0089] The cover plate 400 of one embodiment may include a top surface TF, two short sides SF1 and SF2, and two long sides SF3 and SF4. The cover plate 400 of one embodiment may not include a separate bottom surface. Therefore, the cover plate 400 can be assembled to the bus bar 200 and the insulating layer 300 in a planar direction. The shape of the cover plate 400 on the plane can match the shape of the insulating layer 300 and the end 220.

[0090] In the cover plate 400 of one embodiment, the top surface TF may have a planar shape. For example, the top surface TF may be a surface parallel to a plane formed by the first direction DR1 and the second direction DR2. The two short sides SF1 and SF2 may be arranged along the short side direction of the busbar 200. The two long sides SF3 and SF4 may be arranged along the long side direction of the busbar 200. The two long sides SF3 and SF4 may be formed according to the shapes of the insulating layer 300 and the end 220. The two long sides SF3 and SF4 are thermoformed to match the outer shapes of the busbar 200 and the insulating layer 300, so that the cover plate 400 can be coupled to the busbar 200 and the insulating layer 300 in an assembled manner without the need for a separate adhesive layer.

[0091] Since the third height t3 of the cap plate 400 is greater than the first height t1 of the bus bar 200 and the second height t2 of the insulating layer 300 , the insulating layer 300 and the end portion 220 may be sufficiently accommodated in the third direction DR3 .

[0092] The bottom surface of the assembled bus bar assembly 100 may be exposed from the cap plate 400. The bottom surface of the bus bar assembly 100 may contact the terminal bus bar 22 (see FIG. Figure 3 ). An explanation for this will be provided later.

[0093] Figure 8 is a plan view of a bus bar assembly according to one embodiment.

[0094] Reference Figure 8 , the shape of the busbar assembly 100 on a plane may be the shape of the cover plate 400 on a plane. The shape of the cover plate 400 on a plane may be set along the outer contours of the insulating layer 300 and the end portion 220. The cover plate 400 may have a first width L1 and a second width L2 on a plane. The first width L1 may be the length of the cover end portion 220 (see Figure 7 The second width L2 may be the length of the cover insulating layer 300 (see Figure 7 ). The second width L2 may be greater than the first width L1. In addition, the width here may be a length measured in the second direction DR2.

[0095] Fig. 9 is a side view of a bus bar assembly according to one embodiment.

[0096] Reference Fig. 9 , the shape of the busbar assembly 100 on the side surface may be the shape of the cover plate 400 on the side surface. The cover plate 400 of one embodiment may have a rectangular shape on the side surface. The thickness of the cover plate 400 may be a third thickness t3. Specifically, the cover plate 400 may have a constant thickness in the first longitudinal direction DR1.

[0097] Reference together Figure 7 , Figure 8 and Fig. 9 The bus bar assembly 100 of one embodiment may be assembled by fitting the cap plate 400 to the shapes of the insulating layer 300 and the end portion 220 on a plane.

[0098] Fig.10 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0099] Reference Fig.10, in the cross section corresponding to the AA' cutting line, the inner surface of the cap plate 400 may contact the end portion 220. Specifically, the cap plate 400 may contact the side of the end portion 220. Since the third height t3 of the cap plate 400 is greater than the first height t1 of the end portion 220, the cap plate 400 can fully accommodate the end portion 220 and the bolt BT therein. Figure 3 ) of the terminal bus bar 22 (see Figure 3 ) can be connected to the lower portion and end 220 of the bolt BT.

[0100] Fig.11 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0101] Reference Fig.11 , in the cross section corresponding to the BB' cutting line, the inner surface of the cap plate 400 may contact the insulating layer 300. Specifically, the inner surface of the cap plate 400 may contact the side of the insulating layer 300. Since the third height t3 of the cap plate 400 is greater than the second height t2 of the insulating layer 300, the cap plate 400 may fully accommodate the bus bar 200 and the insulating layer 300 therein.

[0102] Reference together Fig.10 and Fig.11 , the cover plate 400 of the present disclosure has a first width L1 and a second width L2 different from each other on a plane. The first width L1 is a width considering the outer shape of the end 220 of the bus bar 200, and the second width L2 is a width considering the outer shape of the insulating layer 300. Therefore, the cover plate 400 can be assembled and coupled to the bus bar 200 and the insulating layer 300 on a plane without a separate adhesive layer.

[0103] In addition, the embodiment of the cover plate 400 is not limited thereto.

[0104] Fig.12 is an exploded perspective view of a bus bar assembly according to one embodiment.

[0105] Reference Fig.12 , a bus bar assembly 100 - a of one embodiment may include a bus bar 200 , an insulating layer 300 , and a cover plate 400 - a . Fig.12 , for convenience of explanation, there is also shown a fastening member BT coupled to the end portion 220 of the bus bar 200. As an example of the fastening member BT, a bolt is shown.

[0106] Fig.12 The cover plate 400-a shown may have Figure 7 The cap plate 400 shown has different shapes. Specifically, the cap plate 400 - a of one embodiment may match the shapes of the insulating layer 300 and the end portion 220 on the side surface.

[0107] The cover plate 400 - a of one embodiment may include a top surface TF, two short side surfaces SF1 and SF2 , a long side surface SF3 , and a bottom surface BF. Figure 7 Compared to the cover plate 400 shown in FIG. 1 , the cover plate 400 - a has one long side SF4 omitted (see FIG. Figure 7 ) structure, and may further include a bottom surface BF. Thus, the cover plate 400-a can be coupled to the bus bar 200 and the insulating layer 300 in a side direction in an assembled manner. The shape of the cover plate 400 on a plane may match the shape of the insulating layer 300 and the end portion 220.

[0108] In the cover plate 400-a of one embodiment, the top surface TF may be formed along the shape of the insulating layer 300 and the end portion 220. Specifically, the top surface TF may be formed to include steps along the top surface of the insulating layer 300 and the top surface of the end portion 220. Two short side surfaces SF1 and SF2 may be arranged along the short side direction of the busbar 200. One long side surface SF3 may be arranged along the long side direction of the busbar 200. In one embodiment, one long side surface SF3 may cover the end portion 220 and one side of the insulating layer 300. The bottom surface BF may cover the bottom surface of the insulating layer 300. The bottom surface of the end portion 220 of the busbar 200 is exposed from the cover plate 400 and may contact the terminal busbar 22 (see Figure 3 ).

[0109] One side of the cover plate 400-a of one embodiment is omitted, and the top surface TF is thermoformed to match the outer shape of the insulating layer 300 and the bus bar 200, and thus, can be coupled to the bus bar 200 and the insulating layer 300 in a side direction in an assembled manner. That is, the cover plate 400-a can be fastened to the bus bar 200 and the insulating layer 300 without a separate adhesive layer.

[0110] In addition, the material, formation method, insulation performance and heat resistance of the cover plate 400-a can be similarly applied to the above reference Figure 7 Description of the cover plate 400 is described.

[0111] Fig.13 is a plan view of a bus bar assembly according to one embodiment.

[0112] Reference Fig.13 , the shape of the busbar assembly 100-a on a plane may be the shape of the cover plate 400-a on a plane. The cover plate 400-a on a plane may have a rectangular shape. At this time, the cover plate 400-a may have a third width L3. Specifically, the cover plate 400-a may have a constant width along the first direction DR1 (the first direction DR1 is a longitudinal direction).

[0113] Fig.14is a side view of a bus bar assembly according to one embodiment.

[0114] Reference Fig.14 , the shape of the busbar assembly 100-a on the side surface may be the shape of the cover plate 400-a on the side surface. The shape of the cover plate 400-a on the side surface may be set along the outer contour of the insulating layer 300 and the end portion 220. The cover plate 400-a may have a fourth thickness t4 and a fifth thickness t5 on the side surface. The fourth thickness t4 may be the thickness of the cover plate 400-a. Fig.12 ) and the thickness of the bolt BT. The fifth thickness t5 may be the thickness of the cover insulating layer 300 (see Fig.12 The fifth thickness t5 may be greater than the fourth thickness t4.

[0115] Fig.15 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0116] See also Fig.15 In the cross section corresponding to the CC' cutting line, the inner surface of the cover plate 400-a may be spaced apart from the end portion 220 by a predetermined gap GP in the second direction DR2. Fig.12 ), one side of the end portion 220 can be exposed from the cap plate 400-a. In addition, since one side of the exposed end portion 220 is assembled to face the battery module 1200 (see Figure 3 ), thus physically protecting it from external flames.

[0117] The end portion 220 and the bolt BT may be accommodated in the cover plate 400-a. Since the fourth height t4 of the cover plate 400-a is greater than the first height t1 of the end portion 220, the cover plate 400-a can fully accommodate the end portion 220 and the bolt BT therein. Figure 3 ) of the terminal bus bar 22 (see Figure 3 ) can be connected to the lower portion and end 220 of the bolt BT.

[0118] Fig.16 is a cross-sectional view of a bus bar assembly according to one embodiment.

[0119] Reference Fig.16 , in the cross section corresponding to the D-D' cutting line, the inner surface of the cap plate 400-a may contact the insulating layer 300. Specifically, the inner surface of the cap plate 400-a may contact one side surface of the insulating layer 300. Since the cap plate 400-a includes only one long side surface SF3 (see Fig.12), so one side 300-SF of the insulating layer 300 may be exposed from the cap plate 400-a. When one side 300-SF of the insulating layer 300 is exposed, when a flame is generated inside, the gas generated in the insulating layer 300 may be easily discharged to the outside.

[0120] In addition, since the cap plate 400-a is inserted into the insulating layer 300 and the bus bar 200 on the side surface, the inner surface of the cap plate 400-a may contact the insulating layer 300 in the third direction DR3. Therefore, the fifth thickness t5 of the cap plate 400-a may be set considering the second thickness t2 of the insulating layer 300.

[0121] Reference together Fig.12 , Fig.15 and Fig.16 The cover plate 400-a of the present disclosure includes only one long side SF3 (see Fig.12 ), and the other long side faces are omitted, and the cover plate 400-a can be assembled into the insulating layer 300 and the bus bar 200 in the lateral direction. In addition, the cover plate 400-a has a fourth thickness t4 and a fifth thickness t5 different from each other on the side surface. The fourth thickness t4 is a thickness for accommodating the bolt BT and the end 220 of the bus bar 200, and the fifth thickness t5 is a thickness in consideration of the outer shape of the insulating layer 300. Therefore, the cover plate 400-a can be assembled and coupled to the bus bar 200 and the insulating layer 300 without a separate adhesive layer on the side.

[0122] The cover plate 400 - a of the present disclosure extends from the insulating layer 300 and covers the end portion 220 of the bus bar 200 , thereby improving the fire resistance and insulation performance of the bus bar assembly 100 without a separate cap.

[0123] Fig.17 is a side view of a bus bar assembly connecting battery modules according to one embodiment.

[0124] Reference Fig.17 The bus bar assembly 100 of one embodiment can electrically connect the adjacent first battery module 1200-a and second battery module 1200-b. The bus bar assembly 100 includes a cover plate 400 of one embodiment (see Figure 7 ). As mentioned above Figures 7 to 11 As described, the lower surface of the busbar assembly 100 is formed from the cover plate 400 (see Figure 7 ) are exposed and can therefore be electrically connected to the first battery module 1200-a and the second battery module 1200-b.

[0125] When the bus bar assembly 100 is exposed to flame or reaches high temperatures, the insulation layer 300 (see Figure 7) generates gas. The gas generated in the insulating layer 300 may accelerate internal ignition and weaken the structural stability of the busbar assembly 100, thereby adversely affecting the insulation performance of the busbar 200. In addition, the gas generated in the insulating layer 300 may contain carbonized components, however, if the carbonized components accumulate inside, they may adversely affect the electrical insulation characteristics. Since the lower surface of the busbar assembly 100 of the present disclosure is exposed from the cover plate 400 (see Figure 7 ) is exposed, so the gas generated in the insulating layer 300 can be easily discharged to the outside.

[0126] Fig.18 is a side view of a bus bar assembly connecting battery modules according to one embodiment.

[0127] Reference Fig.18 The bus bar assembly 100-a of one embodiment can electrically connect the adjacent third battery module 1200-c and the fourth battery module 1200-d. The bus bar assembly 100-a includes a cover plate 400-a of one embodiment (see Fig.12 ) so that the lower surface can be electrically connected to the third battery module 1200-c and the fourth battery module 1200-d.

[0128] like Figures 12 to 16 As shown, one side of the busbar assembly 100-a can be connected from the cover plate 400-a (see Fig.12 ) is exposed. One exposed side of the bus bar assembly 100-a is assembled to face the third battery module 1200-c and the fourth battery module 1200-d, so that it can be physically protected from external flames. In addition, since one exposed side of the bus bar assembly 100-a is protected from external flames, the gas generated inside the bus bar assembly 100-a can be discharged to the outside.

[0129] Fig.19 is a plan view of a bus bar assembly connecting battery modules according to one embodiment.

[0130] exist Fig.19 , first to fourth battery modules 1200 - a , 1200 - b , 1200 - c , and 1200 - d , a first bus bar assembly 100 , and a second bus bar assembly 100 - a are shown. Fig.19 The above example Fig.17 The first battery module 1200-a and the second battery module 1200-b described in the above are arranged to face Fig.18 The third battery module 1200-c and the fourth battery module 1200-d described in the above. Fig.17 The second bus bar assembly 100-a is the bus bar assembly 100 described in Fig.18The bus bar assembly 100 - a described in .

[0131] Reference Fig.19 When two bus bar assemblies 100 and 100 - a are arranged adjacent to each other, one of the two bus bar assemblies may be applied Figure 7 In the case of the bus bar assembly 100 shown, another embodiment can be applied Fig.12 That is, the first bus bar assembly 100 has a structure in which the lower surface is exposed from the cover plate 400 (see FIG. Figure 7 ), the second bus bar assembly 100-a has a structure in which one side is exposed from the cover plate 400-a (see Fig.12 ). Therefore, one side of the cover plate 400 (see Figure 7 ) is arranged between the two bus bar assemblies 100 and 100 - a , thereby preventing a short circuit from occurring.

[0132] In addition, the exposed lower surface of the first bus bar assembly 100 faces the first battery module 1200-a and the second battery module 1200-b. Therefore, the gas exhausted from the first bus bar assembly 100 during a fire does not directly affect the second bus bar assembly 100-a. In addition, one exposed side of the second bus bar assembly 100-a is arranged to face the third battery module 1200-c and the fourth battery module 1200-d. Therefore, the gas exhausted from the second bus bar assembly 100-a during a fire does not directly affect the first bus bar assembly 100.

[0133] The busbar assembly of the present invention includes a cover plate that can replace the cap, thereby improving insulation performance and fire resistance. In addition, when exposed to flames, the busbar assembly of the present invention can allow the gas generated inside it to be easily discharged to the outside while maintaining the fire resistance, insulation and stability of adjacent busbar assemblies and preventing the spread of flames.

[0134] In this embodiment, terms indicating directions such as the front side, the back side, the left side, the right side, the upper side, and the lower side are used, but the terms used are provided only for the convenience of description and may become different depending on the position of the object, the position of the observer, etc.

[0135] One or more battery modules according to the embodiments of the present disclosure described above may be installed together with various control and protection systems such as a BMS (Battery Management System), a BDU (Battery Disconnect Unit), and a cooling system to form a battery pack.

[0136] The battery module or battery pack can be applied to various devices. Specifically, it can be applied to vehicle devices such as electric bicycles, electric vehicles and hybrid electric vehicles, or ESS (Energy Storage System), and can be applied to various devices that can use secondary batteries, without limitation thereto.

[0137] Although the present invention has been described in detail with reference to the preferred embodiments of the present invention, the scope of the present disclosure is not limited thereto, and those skilled in the art may make various modifications and improvements using the basic concepts of the present disclosure, which are defined by the appended claims and also fall within the scope of the present disclosure.

Claims

1. A bus bar assembly, comprising: A bus bar including a main body and end portions extending from both ends of the main body and defining through holes; an insulating layer, the insulating layer surrounding the main body; as well as A cover plate covers the insulating layer and the end portion and has an integral shape.

2. The bus bar assembly according to claim 1, wherein: The cover plate exposes one surface of the insulating layer.

3. The bus bar assembly according to claim 1, wherein: The shape of the cover plate in a plane is arranged along the outer contours of the insulating layer and the end portion.

4. The bus bar assembly according to claim 1, wherein: The shape of the cover plate on the side surface is arranged along the outer contours of the insulating layer and the end portion.

5. The bus bar assembly according to claim 1, wherein: The cover plate comprises: Top surface; two short side surfaces, the two short side surfaces being arranged in a short side direction of the bus bar; and Two long side surfaces are provided in the long side direction of the bus bar and are formed along the shapes of the insulating layer and the end portion.

6. The bus bar assembly according to claim 1, wherein: The cover plate comprises: a top surface formed along the shapes of the insulating layer and the end portion; Two short side surfaces, the two short side surfaces are arranged in the short side direction of the bus bar; a long side surface, the long side surface being arranged in a long side direction of the bus bar; and A bottom surface faces the top surface and is formed along the shape of the insulating layer.

7. The bus bar assembly according to claim 1, wherein: The insulating layer is subjected to ceramization at high temperature.

8. A bus bar group, comprising: at least one busbar assembly according to any one of claims 1 to 7; Battery modules; A battery disconnect unit BDU module, which is used to control the electrical connection of the battery module; as well as A battery management system (BMS) module that monitors and controls the operation of the battery modules, The at least one bus bar assembly is electrically connected to at least one of between the battery modules, between the battery module and the BDU module, between the battery module and the BMS module, and between the BDU module and the BMS module.

9. The bus bar assembly according to claim 8, further comprising a fastening portion coupled to the through hole of the at least one bus bar assembly, in, The cover plate covers the fastening portion.

10. The bus bar assembly according to claim 8, wherein: The battery module includes a first battery module, a second battery module adjacent to the first battery module, a third battery module facing the first battery module, and a fourth battery module adjacent to the third battery module and facing the second battery module. The at least one bus bar assembly includes: a first bus bar assembly connecting the first battery module and the second battery module; and a second bus bar assembly connecting the third battery module and the fourth battery module and facing the first bus bar; The first bus bar assembly is configured such that a bottom surface is exposed from the cover plate, and The second bus bar assembly is configured such that one side is exposed from the cover plate.

11. The bus bar assembly according to claim 10, wherein: The exposed bottom surface of the first bus bar assembly faces the first battery module and the second battery module, and An exposed one side surface of the second bus bar assembly faces the third battery module and the fourth battery module.

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