Rechargeable battery module, method of manufacturing the same, and system for the same

Abstract

The present disclosure relates to a rechargeable battery module, a method of manufacturing the same, and a system therefor. The rechargeable battery module may include: a plurality of battery cells stacked in a first direction; a bus bar holder configured to at least partially cover the plurality of battery cells while exposing electrode terminals of the plurality of battery cells upward; a bus bar connecting the electrode terminals of the plurality of battery cells exposed by a bus bar support portion of the bus bar holder; a flexible printed circuit (FPC) forming an exposure hole in a vertical direction perpendicular to the first direction, the flexible printed circuit being disposed on and electrically connected to the bus bar to expose a copper thin film portion of the flexible printed circuit in a direction toward the bus bar; and a metal tab inserted inside the flexible printed circuit, the metal tab being electrically connected to a surface of the copper thin film portion and being exposed outward through the exposure hole.

Description

Technical Field

[0001] The present invention relates to a rechargeable battery module in which a metal tab for electrical connection to a bus bar is built in a flexible printed circuit (FPC). Background Art

[0002] Unlike primary batteries, rechargeable batteries can be charged and discharged repeatedly. Small-capacity rechargeable batteries are used in small portable electronic devices such as mobile phones, notebook computers, and camcorders.

[0003] High capacity and high density rechargeable batteries are used for power or energy storage to drive motors in hybrid and electric vehicles. Rechargeable batteries can be used in rechargeable battery modules including multiple battery cells connected in series and / or parallel to drive motors of hybrid vehicles, for example, which require relatively high energy density.

[0004] For example, the rechargeable battery module connects a flexible printed circuit (FPC) and a bus bar made of aluminum or copper to measure a cell voltage, for example, by using an intermediate medium including a nickel tab.

[0005] By using a nickel tab as an intermediate medium, a first end of the nickel tab is connected to a flexible printed circuit by welding, and a second end of the nickel tab is connected to a bus bar by laser welding. The method of using a nickel tab increases raw material costs and reduces the cost competitiveness of a rechargeable battery module. Summary of the invention

[0006] The present disclosure provides a rechargeable battery module which reduces manufacturing cost and process time by having a metal tab built in a flexible printed circuit (FPC).

[0007] A rechargeable battery module may include: a plurality of battery cells stacked in a first direction; a bus bar support configured to upwardly expose electrode terminals of the plurality of battery cells and at least partially cover the plurality of battery cells; a bus bar connecting the electrode terminals of the plurality of battery cells exposed through a bus bar supporting portion of the bus bar support; a flexible printed circuit (FPC) having an exposure hole formed in a vertical direction perpendicular to the first direction, the flexible printed circuit being arranged on the bus bar and electrically connected to the bus bar to expose a copper film portion of the flexible printed circuit in a direction toward the bus bar; and a metal wiring tab inserted into the interior of the flexible printed circuit, the metal wiring tab being electrically connected to a surface of the copper film portion and exposed outwardly through the exposure hole.

[0008] The copper thin film portion may be formed to a thickness of 1 oz.

[0009] The metal tab may be formed to have a thickness of 0.1 to 0.2 mm.

[0010] The flexible printed circuit may include: a signal line configured to transmit a sensing signal; a connecting line configured to connect the copper thin film portion to the signal line; and a covering portion configured to at least partially cover the signal line, the copper thin film portion, and the connecting line, exposing a portion of the copper thin film portion on a first side of the flexible printed circuit and exposing a portion of the metal wiring sheet on a second side of the flexible printed circuit.

[0011] The exposure hole may include a first exposure hole exposing the copper film portion in the direction toward the bus bar and a second exposure hole exposing a portion of the metal wiring piece, and the covering portion may include a first covering layer and a second covering layer, the first covering layer forming the first exposure hole, wherein the copper film portion and the metal wiring piece are interposed between the first covering layer and the second covering layer, and the second covering layer forming the second exposure hole.

[0012] An adhesive may be applied on an inner surface of each of the first coverlay and the second coverlay to fix the copper thin film portion and the metal tab at a position between the first coverlay and the second coverlay.

[0013] The flexible printed circuit may further include a slot hole configured to at least partially surround the outer circumference of the copper film portion and penetrate the covering portion, the slot hole having a first end and a second end, the first end and the second end of the slot hole being arranged on respective sides of the connecting line in the width direction.

[0014] The signal line may be formed at one side of the flexible printed circuit in a width direction and extend in a length direction of the flexible printed circuit.

[0015] The copper thin film portion may be inserted between the first covering layer and the second covering layer, and a portion of a surface of a first side of the copper thin film portion is exposed through the first exposure hole, and a portion of a surface of a second side of the copper thin film portion faces the second exposure hole and is electrically connected to the metal wiring sheet.

[0016] When the metal tab, the copper thin film portion, and the bus bar are in surface contact with each other, they may be electrically connected to each other by welding.

[0017] The copper thin film portion may be inserted between the first cover layer and the second cover layer with a first area size, and the metal wiring tab may have a first surface and a second surface, the first surface being electrically connected to the surface of the second side of the copper thin film portion, and a portion of the second surface being exposed through the second exposure hole of the second cover layer.

[0018] The second cover layer may include a step portion on an edge portion of the metal tab, and the step portion may be formed on an inner surface of the second exposure hole of the second cover layer.

[0019] According to some embodiments, a method for manufacturing a rechargeable battery module is provided, the method comprising: stacking a plurality of battery cells in a first direction; providing a bus bar bracket so that the bus bar bracket at least partially covers the plurality of battery cells while exposing electrode terminals of the plurality of battery cells; connecting the electrode terminals of the plurality of battery cells via a bus bar, the electrode terminals of the plurality of battery cells being exposed through a bus bar supporting portion of the bus bar bracket; providing a flexible printed circuit (FPC) on the bus bar and electrically connecting the flexible printed circuit to the bus bar, the flexible printed circuit forming an exposure hole in a vertical direction perpendicular to the first direction and exposing a copper film portion of the flexible printed circuit in a direction toward the bus bar; and inserting a metal wiring tab into the interior of the flexible printed circuit and electrically connecting the metal wiring tab to a surface of the copper film portion, the metal wiring tab being exposed outwardly through the exposure hole of the flexible printed circuit.

[0020] In some embodiments, the copper film portion has a thickness of 1 oz. In some embodiments, the metal terminal piece has a thickness of 0.1-0.2 mm.

[0021] In some embodiments, the flexible printed circuit includes: a signal line configured to transmit a sensing signal; a connecting line configured to connect the copper film portion to the signal line; and a covering portion configured to at least partially cover the signal line, the copper film portion and the connecting line, exposing a portion of the copper film portion on a first side of the flexible printed circuit and exposing a portion of the metal wiring sheet on a second side of the flexible printed circuit.

[0022] In some embodiments, the exposure hole may include a first exposure hole exposing the copper film portion in the direction toward the bus bar and a second exposure hole exposing a portion of the metal wiring piece, and the covering portion includes: a first covering layer forming the first exposure hole; and a second covering layer, wherein the copper film portion and the metal wiring piece are interposed between the first covering layer and the second covering layer, and the second covering layer forms the second exposure hole.

[0023] In some embodiments, the method further includes applying an adhesive on an inner surface of each of the first coverlay and the second coverlay to fix the copper film portion and the metal tab to corresponding positions between the first coverlay and the second coverlay.

[0024] In some embodiments, the method further includes forming a slot at least partially surrounding the periphery of the copper film portion and penetrating the covering portion, the slot having a first end and a second end, the first end and the second end of the slot being arranged on respective sides of the connecting line in the width direction.

[0025] According to some embodiments, a system for a rechargeable battery module is provided, the system comprising: a bus bar; and a flexible printed circuit (FPC) disposed on and electrically connected to the bus bar, the flexible printed circuit comprising: an exposure hole formed in the flexible printed circuit in a vertical direction; a copper film portion, the copper film portion being exposed in a direction toward the bus bar; and a metal wiring tab inserted into the interior of the flexible printed circuit, the metal wiring tab being electrically connected to a surface of the copper film portion and exposed to the outside through the exposure hole.

[0026] According to an embodiment, by inserting a metal terminal tab into the inside of the cover portion of the flexible printed circuit, the metal terminal tab can be electrically connected to the bus bar by sandwich welding in a state of being disposed on the surface of the copper film portion. Therefore, according to this embodiment, during the process of manufacturing the flexible printed circuit, a conventional welding process for connecting the metal terminal tab may not be required, thereby streamlining the manufacturing process and reducing the manufacturing cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is an exploded perspective view schematically illustrating a rechargeable battery module according to a first embodiment.

[0028] Figure 2 For schematic illustration, installation Figure 1 A perspective view of a flexible printed circuit in a bus bar holder.

[0029] Figure 3FIG. 1 is a top view schematically illustrating a flexible printed circuit according to a first embodiment.

[0030] Figure 4 Insert for illustrative purposes Figure 3 Top view of the copper film part and metal terminal piece in the flexible printed circuit.

[0031] Figure 5 An exploded perspective view schematically illustrating a flexible printed circuit mounted with a copper film portion and a metal tab, the flexible printed circuit being laser welded (Lw) to a bus bar.

[0032] Figure 6 For along Figure 4 A cross-sectional view of a flexible printed circuit taken along line AA, wherein a copper film portion and a metal tab are inserted into the flexible printed circuit, and the flexible printed circuit is laser welded to a bus bar.

[0033] Figure 7 is a diagram schematically illustrating a flexible printed circuit according to a second embodiment.

[0034] Figure 8 For illustrative purposes Figure 7 A top view of a portion of a flexible printed circuit in which a copper film portion and a metal terminal piece are inserted therein and electrically connected thereto.

[0035] <Description of Reference Numerals>

[0036] 10: Battery cell 11, 12: Electrode terminal

[0037] 13: Exhaust port 20: Bus bar bracket

[0038] 21: Busbar support part 22: Exhaust part

[0039] 30: Busbar 40, 140: Flexible printed circuit

[0040] 41: Signal line 43: Connection line

[0041] 45, 145: Covering part 45a: First covering layer

[0042] 45b: second covering layer 45c: first exposure hole

[0043] 45d: second exposure hole 45e: stepped portion

[0044] 46: Adhesive 47, 147: Slot

[0045] 50: Copper film part 60: Metal connecting piece

[0046] 100: Rechargeable battery module DETAILED DESCRIPTION

[0047] Hereinafter, the present invention will be more fully described with reference to the accompanying drawings, in which embodiments of the present invention are shown. As will be appreciated by those skilled in the art, the described embodiments may be modified in various ways, all without departing from the spirit or scope of the present invention. The accompanying drawings and descriptions should be considered to be illustrative and non-restrictive in nature. Throughout the specification, the same reference numerals represent the same elements.

[0048] Figure 1 is an exploded perspective view schematically illustrating a rechargeable battery module according to a first embodiment. Figure 2 For schematic illustration, installation Figure 1 A perspective view of a flexible printed circuit in a bus bar holder.

[0049] like Figure 1 and Figure 2 , a rechargeable battery module 100 according to an embodiment includes: a plurality of battery cells 10 stacked in a first direction; a bus bar support 20 configured to expose electrode terminals 11, 12 of the battery cells 10 upward and at least partially cover the battery cells 10; a bus bar 30 connecting the electrode terminals 11, 12 exposed through a bus bar support portion 21 of the bus bar support 20; a flexible printed circuit (FPC) 40 formed in a vertical direction (z-axis direction) perpendicular to the first direction (in a vertical direction) ... Figure 6 The copper film portion 50 is exposed in a direction toward the bus bar 30 (for example, referring to FIG. 1 ). Figure 5 and a metal wiring sheet 60, which is inserted into the interior of the flexible printed circuit 40 and is electrically connected to the surface of the copper film portion 50.

[0050] The rechargeable battery module 100 of the present embodiment may include a frame (not shown) of various structures accommodating a plurality of battery cells 10 therein. Hereinafter, a detailed description of the configuration of the frame accommodating the battery cells 10 will be omitted, and the main configuration of the present embodiment will be described.

[0051] A plurality of battery cells 10 may be formed as a rechargeable battery and may be stacked in a first direction (eg, x-axis direction). A pair of end plates may be provided at both ends of the stacked battery cells 10 in the first direction and may support the battery cells 10 in the first direction (eg, x-axis direction).

[0052] A pair of side plates may be disposed on both sides of the battery cell 10 in a second direction (e.g., y-axis direction) intersecting the first direction (e.g., perpendicular to the first direction) and connected to a pair of end plates to support the battery cell 10 in the second direction (e.g., y-axis direction).

[0053] The bus bar holder 20 may include a bus bar supporting portion 21 for connection and insulation of the electrode terminals 11 , 12 of the battery cells 10 and a gas exhaust portion 22 for exhausting exhaust gas of the battery cells 10 .

[0054] The bus bar support portion 21 may expose the electrode terminals 11, 12 in a third direction (e.g., z-axis direction) and cover an upper portion of the battery cell 10. Here, the third direction refers to a direction intersecting (e.g., perpendicular to) the first direction (e.g., x-axis direction) and the second direction (e.g., y-axis direction).

[0055] The vent portion 22 corresponds to the vent port 13 of the battery cell 10 , and when the vent port 13 is opened, the opening pressure and exhaust of the battery cell 10 may be discharged to the outside of the bus bar holder 20 .

[0056] The bus bar 30 may be welded to the electrode terminals 11 , 12 exposed through the bus bar support portion 21 in the third direction so that the electrode terminals 11 , 12 may be electrically and mechanically connected.

[0057] That is, the bus bar 30 may connect the electrode terminals 11 , 12 of the battery cells 10 adjacent to each other in a first direction (eg, the x-axis direction) in parallel or connect the electrode terminals 11 , 12 of the battery cells 10 adjacent to each other in series.

[0058] The bus bar support portions 21 corresponding to the electrode terminals 11 and 12 in the second direction (e.g., the y-axis direction) can be arranged on both sides of the battery module 100, and the exhaust portion 22 corresponding to the exhaust port 13 provided between the electrode terminals 11 and 12 in the second direction (e.g., the y-axis direction) can be arranged between the bus bar support portions 21.

[0059] The flexible printed circuit 40 may be disposed on the bus bar 30 and electrically connected to the bus bar 30 , and has a copper thin film portion 50 and a metal tab 60 exposed in a third direction (eg, z-axis direction) and located inside the flexible printed circuit.

[0060] Figure 3 FIG. 1 is a top view schematically illustrating a flexible printed circuit according to a first embodiment. Figure 4 Insert for illustrative purposes Figure 3 Top view of the copper film part and metal terminal piece in the flexible printed circuit.

[0061] refer to Figure 3 and Figure 4In more detail, the flexible printed circuit 40 may include a signal line 41 configured to transmit a sensing signal, a connecting line 43 configured to connect the copper film portion 50 to the signal line 41, and a covering portion 45, which is configured to: at least partially cover the signal line 41, the copper film portion 50 and the connecting line 43; expose a portion of the copper film portion 50 on a first side of the flexible printed circuit 40 in a first direction; and expose a portion of the metal wiring piece 60 on a second side of the flexible printed circuit 40.

[0062] The signal line 41 is formed on one side in the width direction (eg, y-axis direction) of the flexible printed circuit 40 , and extends in the length direction of the flexible printed circuit 40 .

[0063] The connection line 43 may connect the copper thin film portion 50 to the signal line 41 .

[0064] The copper film portion 50 is electrically connected to the bus bar 30 by soldering and may be configured to detect connection of the battery cell 10 with the bus bar 30 via the copper film portion 50 inserted into the inside of the flexible printed circuit 40 and transmit a detection signal to the connection line 43 and the signal line 41 .

[0065] The copper thin film portion 50 may be inserted into the inside of the flexible printed circuit 40 such that a portion of the copper thin film portion 50 may be exposed at a lower portion of the cover portion 45 when the copper thin film portion 50 is inserted into the inside of the cover portion 45 of the flexible printed circuit 40 .

[0066] The copper film portion (eg, copper foil) 50 may have a thickness of 35 μm, ie, 1 oz. A copper film portion having a thickness of 1 oz or more rapidly increases the cost of the flexible printed circuit 40 and is not widely used.

[0067] The copper thin film portion 50 has excellent welding characteristics when the thickness is at least 100 μm, but when the thickness of the copper thin film portion 50 is less than 100 μm, the welding strength is generally reduced and laser welding becomes difficult. The present embodiment can achieve stable welding strength even in the flexible printed circuit 40 using the copper thin film portion 50 of 35 μm thickness.

[0068] Regarding the copper thin film portion 50, a portion of the first side surface (ie, the surface of the first side) of the copper thin film portion 50 is exposed through the first exposure hole 45c (see FIG. 4A ) formed on the first side of the flexible printed circuit 40. Figure 6 ) is exposed to the outside, and a portion of the second side surface (ie, the surface of the second side) of the copper thin film portion 50 faces the second exposure hole 45d (see Figure 6 ) and is electrically connected to a metal tab 60. The metal tab 60 may be electrically connected to the surface, as explained in more detail when describing the covering portion 45.

[0069] The covering portion 45 may include a first covering layer 45a and a second covering layer 45b (see Figure 6 ), when the copper thin film portion 50 is located in the flexible printed circuit 40, the first cover layer 45a and the second cover layer 45b cover the copper thin film portion 50 and the metal wiring sheet 60. As an example, the cover portion 45 may be formed of polyimide and coated with an adhesive 46.

[0070] That is, an adhesive may be applied on the inner surface of each of the first coverlay 45a and the second coverlay 45b to fix the copper thin film portion 50 and the metal tab 60 to a position between the first coverlay 45a and the second coverlay 45b.

[0071] The slot hole 47 may surround the outer circumference of the copper thin film portion 50 and penetrate the cover portion 45 , and may have both ends formed at both sides in the width direction of the connection line 43 .

[0072] The first cover layer 45 a forms a first side surface of the flexible printed circuit 40 , and a first exposure hole 45 c may be formed to expose the copper thin film portion 50 in a direction toward the bus bar 30 , which is a third direction.

[0073] The first exposure hole 45c may be a polygonal shape, a circular shape, etc., and may be formed so that a portion of the surface of the copper thin film portion 50 may be exposed to the first side of the flexible printed circuit 40 through the first exposure hole 45c. Therefore, the bus bar 30 may be electrically connected to the copper thin film portion 50 through the first exposure hole 45c.

[0074] The second cover layer 45 b may form a second side surface of the flexible printed circuit 40 at a position opposite to the first cover layer 45 a .

[0075] The second exposure hole 45 d may be formed in the second cover layer 45 b at a position corresponding to the first exposure hole 45 c formed in the first cover layer 45 a .

[0076] The second exposure hole 45 d may be in a polygonal shape, a circular shape, etc., and may be formed so that a portion of the surface of the copper thin film portion 50 may be exposed to the second side of the flexible printed circuit 40 through the second exposure hole 45 d .

[0077] Therefore, a portion of the metal tab 60 inserted between the first cover layer 45 a and the second cover layer 45 b may be exposed to the outside through the second exposure hole 45 d .

[0078] Figure 5 An exploded perspective view schematically illustrating a flexible printed circuit mounted with a copper film portion and a metal tab, the flexible printed circuit being laser welded to a bus bar. Figure 6 For along Figure 4 A cross-sectional view of a flexible printed circuit taken along line AA, wherein a copper film portion and a metal tab are inserted into the flexible printed circuit, and the flexible printed circuit is laser welded to a bus bar.

[0079] like Figure 5 and Figure 6 , when the copper thin film portion 50 is laser welded to the bus bar 30 , the metal tab 60 may be electrically connected to the copper thin film portion 50 , and the copper thin film portion 50 is disposed between the first cover layer 45 a and the second cover layer 45 b .

[0080] That is, the metal terminal 60 is located on the surface of the copper film portion 50 and is initially not electrically connected, and the flexible printed circuit 40 can be located on the upper portion of the bus bar 30 so that when the copper film portion 50 is sandwich laser welded to the bus bar 30, the metal terminal 60 can be electrically connected to the copper film portion 50.

[0081] The metal tab 60 may be formed of, for example, aluminum, nickel, or copper as a metal material that is easily electrically connected to the copper thin film portion 50. In the illustrated embodiment, the metal tab 60 is formed of aluminum, but is not necessarily limited thereto and may be changed to nickel or copper.

[0082] In some embodiments, the metal tab 60 may be formed to a thickness of 0.1 to 0.2 mm.

[0083] Here, when the thickness of the metal tab 60 is less than 0.1 mm, it is difficult to achieve appropriate strength of the portion welded to the copper thin film portion 50 , thereby reducing welding quality.

[0084] In addition, when the thickness of the metal tab 60 is greater than 0.2 mm, a lifting phenomenon due to voids may occur in a stacking process of the cover portion 45 including the first cover layer 45 a and the second cover layer 45 b , thereby degrading manufacturing quality.

[0085] Meanwhile, the copper thin film portion 50 may be located between the first cover layer 45 a and the second cover layer 45 b with a first area size.

[0086] The copper thin film portion 50 may be exposed on both side surfaces opposite to each other through the first and second exposure holes 45c and 45d, while both side edge portions of the copper thin film portion 50 are covered by the first and second cover layers 45a and 45b.

[0087] In addition, for the metal tab 60, the first surface is disposed on the surface of the copper film portion 50, and a portion of the second surface may be exposed through the second exposure hole 45d of the second cover layer 45b. The metal tab 60 may be formed to have a second area size smaller than the first area of ​​the copper film portion 50.

[0088] The metal tab 60 may have a lower surface (i.e., a first surface) electrically connected to the upper surface of the copper thin film portion 50, and both side edges of the metal tab 60 may be covered by the covering portion 45 (e.g., the second covering layer 45b). To this end, the second covering layer 45b may include a step portion 45e located on an edge portion of the metal tab 60, and the step portion 45e may be formed on an inner surface of the second exposure hole 45d of the second covering layer 45b.

[0089] The step portion 45e may be formed in a groove shape recessed from the inner surface of the second exposure hole 45d of the second cover layer 45b. The step portion 45e may be formed along the periphery of the inner wall surface of the second exposure hole 45d so that the entire edge portion of the metal terminal 60 may be inserted therein.

[0090] Therefore, in a state where the edge portion of the metal wiring piece 60 is located in the step portion 45e of the second covering layer 45b forming the covering portion 45, the metal wiring piece 60 is electrically connected to the copper film portion 50, and when the metal wiring piece 60 is inserted into the interior of the covering portion 45, a more stable electrical connection can be achieved.

[0091] That is, inside the covering portion 45, for the metal wiring piece 60, the first surface (e.g., the first side surface) of the metal wiring piece 60 is electrically connected to the copper film portion 50, and a portion of the second surface (e.g., the second side surface) can be exposed to the outside through the second exposure hole 45d of the second covering layer 45b.

[0092] As described above, according to the rechargeable battery module 100 of the present embodiment, when the metal tab 60 is inserted into the inside of the cover portion 45 and disposed on the surface of the copper film portion 50, the metal tab 60 can be electrically connected to the bus bar 30 by sandwich welding. That is, the metal tab 60, the copper film portion 50, and the bus bar 30 are electrically connected to each other by welding when they are in surface contact with each other. Therefore, according to the present embodiment, during the process of manufacturing the flexible printed circuit 40, the conventional welding process for connecting the metal tab to the bus bar may not be required, thereby streamlining the manufacturing process and reducing the manufacturing cost.

[0093] Figure 7 is a diagram schematically illustrating a flexible printed circuit according to a second embodiment. Figure 8 For illustrative purposes Figure 7A top view of a portion of a flexible printed circuit in which a copper film portion and a metal terminal piece are inserted therein and electrically connected thereto. Figures 1 to 6 The same reference numerals as in Figures 7 and 8 hereinafter, detailed descriptions of the same reference numerals will be omitted.

[0094] like Figure 7 and Figure 8 , the flexible printed circuit 140 according to the second embodiment may include a round-shaped cover portion 145 bent in a length direction and a teardrop-shaped slot 147 formed along the outer circumference of the copper thin film portion 50 .

[0095] The slot hole 147 may be formed to surround the outer circumference of the copper thin film portion 50 and penetrate the cover portion 145 .

[0096] In some embodiments, a method for manufacturing a rechargeable battery module described herein is provided. The method may include: (a) stacking a plurality of battery cells in a first direction; (b) providing a bus bar support so that the bus bar support at least partially covers the battery cell while exposing the electrode terminal of the battery cell; (c) connecting the electrode terminal of the battery cell via a bus bar, the electrode terminal of the battery cell being exposed through the bus bar support portion of the bus bar support; (d) providing a flexible printed circuit (FPC) on the bus bar and electrically connecting the flexible printed circuit to the bus bar, the flexible printed circuit forming an exposure hole in a vertical direction perpendicular to the first direction, and exposing a copper film portion of the flexible printed circuit in a direction toward the bus bar; and (e) inserting a metal tab into the interior of the flexible printed circuit and electrically connecting the metal tab to the surface of the copper film portion, the metal tab being exposed outward through the exposure hole of the flexible printed circuit.

[0097] In some embodiments, the method further includes applying an adhesive on an inner surface of each of the first cover layer and the second cover layer to fix the copper film portion and the metal tab to corresponding positions between the first cover layer and the second cover layer.

[0098] In some embodiments, the method further includes forming a slot hole at least partially surrounding the outer circumference of the copper film portion and penetrating the covering portion, the slot hole having a first end and a second end, the first end and the second end of the slot hole being arranged at respective sides in the width direction of the connecting line.

[0099] According to some embodiments, a system for a rechargeable battery module described herein is provided. The system may include one or more components described herein, including, for example, a bus bar and a flexible printed circuit (FPC) disposed on the bus bar and electrically connected to the bus bar. As described herein, the flexible printed circuit may include: an exposure hole formed in the flexible printed circuit in a vertical direction; a copper film portion, the copper film portion is exposed in a direction toward the bus bar; and a metal tab inserted into the interior of the flexible printed circuit, the metal tab being electrically connected to the surface of the copper film portion and exposed outwardly through the exposure hole.

[0100] While the invention has been described in connection with what are presently considered to be practical embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but on the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the purview of the appended claims.

Claims

1. A rechargeable battery module comprising: A plurality of battery cells are stacked in a first direction; a bus bar support configured to at least partially cover the plurality of battery cells while exposing electrode terminals of the plurality of battery cells; a bus bar connecting the electrode terminals of the plurality of battery cells exposed through the bus bar supporting portion of the bus bar support; a flexible printed circuit having an exposure hole formed in a vertical direction perpendicular to the first direction, the flexible printed circuit being disposed on the bus bar and electrically connected to the bus bar so as to expose a copper thin film portion of the flexible printed circuit in a direction toward the bus bar; as well as A metal tab is inserted into the interior of the flexible printed circuit, the metal tab being electrically connected to a surface of the copper thin film portion and being exposed to the outside through the exposure hole. 2 . The rechargeable battery module according to claim 1 , wherein the copper thin film portion is formed to a thickness of 1 oz. 3 . The rechargeable battery module according to claim 1 , wherein the metal tab is formed to a thickness of 0.1 to 0.2 mm.

4. The rechargeable battery module according to claim 1, wherein the flexible printed circuit comprises: a signal line configured to transmit a sensing signal; a connecting line configured to connect the copper film portion to the signal line; as well as The overlay is configured with: at least partially covering the signal line, the copper film portion and the connecting line; exposing a portion of the copper thin film portion at a first side of the flexible printed circuit; and A portion of the metal tab is exposed at a second side of the flexible printed circuit.

5. The rechargeable battery module according to claim 4, wherein the exposing holes include a first exposing hole exposing the copper thin film portion in the direction toward the bus bar and a second exposing hole exposing a portion of the metal tab, and The covered part includes: a first covering layer, forming the first exposure hole; as well as A second cover layer, wherein the copper thin film portion and the metal tab are interposed between the first cover layer and the second cover layer, and the second cover layer forms the second exposure hole.

6. The rechargeable battery module according to claim 5, wherein an adhesive is applied on an inner surface of each of the first cover layer and the second cover layer to fix the copper film portion and the metal tab to a position between the first cover layer and the second cover layer.

7. The rechargeable battery module according to claim 5, wherein the flexible printed circuit further comprises: A slot hole is configured to at least partially surround the outer circumference of the copper thin film portion and penetrate the cover portion, the slot hole having a first end and a second end, the first end and the second end of the slot hole being disposed at respective sides in the width direction of the connection line. 8 . The rechargeable battery module according to claim 7 , wherein the signal line is formed at one side in a width direction of the flexible printed circuit and extends in a length direction of the flexible printed circuit.

9. The rechargeable battery module according to claim 8, wherein the copper thin film portion is inserted between the first covering layer and the second covering layer, and a portion of a surface of a first side of the copper thin film portion is exposed through the first exposure hole, and a portion of a surface of a second side of the copper thin film portion faces the second exposure hole and is electrically connected to the metal tab. 10 . The rechargeable battery module according to claim 9 , wherein the metal tab, the copper thin film portion, and the bus bar are electrically connected to each other by welding while being in surface contact with each other.

11. The rechargeable battery module according to claim 10, wherein: The copper film portion is interposed between the first cover layer and the second cover layer with a first area size; and The metal tab has a first surface and a second surface, the first surface being electrically connected to the surface of the second side of the copper thin film portion, and a portion of the second surface being exposed through the second exposing hole of the second cover layer. 12 . The rechargeable battery module of claim 11 , wherein the second cover layer comprises a step portion on an edge portion of the metal tab, the step portion being formed on an inner surface of the second exposure hole of the second cover layer.

13. A method for manufacturing a rechargeable battery module, comprising: stacking a plurality of battery cells in a first direction; providing a bus bar support such that the bus bar support at least partially covers the plurality of battery cells while exposing electrode terminals of the plurality of battery cells; connecting the electrode terminals of the plurality of battery cells via bus bars, the electrode terminals of the plurality of battery cells being exposed through a bus bar supporting portion of the bus bar support; providing a flexible printed circuit on the bus bar and electrically connecting the flexible printed circuit to the bus bar, the flexible printed circuit forming an exposure hole in a vertical direction perpendicular to the first direction and exposing a copper thin film portion of the flexible printed circuit in a direction toward the bus bar; as well as A metal tab is inserted into the interior of the flexible printed circuit and electrically connected to the surface of the copper thin film portion, the metal tab being exposed to the outside through the exposure hole of the flexible printed circuit. The method according to claim 13 , wherein the copper thin film portion has a thickness of 1 oz.

15. The method according to claim 13, wherein the metal tab has a thickness of 0.1 to 0.2 mm.

16. The method of claim 13, wherein the flexible printed circuit comprises: a signal line configured to transmit a sensing signal; a connecting line configured to connect the copper film portion to the signal line; as well as The overlay is configured with: at least partially covering the signal line, the copper film portion and the connecting line; exposing a portion of the copper thin film portion at a first side of the flexible printed circuit; and A portion of the metal tab is exposed at a second side of the flexible printed circuit.

17. The method according to claim 16, wherein the exposing holes include a first exposing hole exposing the copper thin film portion in the direction toward the bus bar and a second exposing hole exposing a portion of the metal tab, and The covered part includes: a first covering layer, forming the first exposure hole; as well as A second cover layer, wherein the copper thin film portion and the metal tab are interposed between the first cover layer and the second cover layer, and the second cover layer forms the second exposure hole.

18. The method of claim 17, further comprising applying an adhesive on an inner surface of each of the first coverlay and the second coverlay to fix the copper thin film portion and the metal tab to a position between the first coverlay and the second coverlay.

19. The method according to claim 17, further comprising forming a slot hole at least partially surrounding the outer periphery of the copper thin film portion and penetrating the covering portion, the slot hole having a first end and a second end, the first end and the second end of the slot hole being arranged at respective sides in a width direction of the connecting line.

20. A system for a rechargeable battery module, the system comprising: Busbars; as well as a flexible printed circuit disposed on the bus bar and electrically connected to the bus bar, the flexible printed circuit comprising: an exposure hole formed in the flexible printed circuit in a vertical direction; a copper thin film portion, the copper thin film portion being exposed in a direction toward the bus bar; and A metal tab is inserted into the interior of the flexible printed circuit, the metal tab being electrically connected to a surface of the copper thin film portion and being exposed to the outside through the exposure hole.

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