Battery module and method for manufacturing battery module

Abstract

Disclosed are a battery module and a method of manufacturing the same, the battery module including a bus bar assembly including a bus bar, a support film supporting the bus bar, and a support plate supporting the support film. Specifically, the battery module includes: a plurality of battery cells arranged in a first direction and each including a cell case and a cell terminal protruding from the cell case; and a bus bar assembly including a bus bar allowing electrical connection between respective cell terminals of at least one pair of battery cells among the plurality of battery cells, a support film coupled to the bus bar to support the bus bar, and a support plate coupled to the support film to support the support film. Accordingly, it is possible to exclude the use of a bus bar holder formed of metal for supporting the bus bar, thereby reducing costs associated therewith, improving assembly productivity, and enabling the battery module to be miniaturized and lightweight.

Description

Technical Field

[0001] The present invention relates to a battery module and a method for manufacturing a battery module. Background Art

[0002] Generally, as the demand for portable electronic products such as laptop computers, cameras, and mobile phones has increased rapidly and with the commercialization of robots and electric vehicles, active research is being conducted on high-performance secondary batteries that can be repeatedly charged and discharged.

[0003] Secondary batteries are widely used as energy supply and storage components not only in small devices such as portable electronic products but also in medium and large devices such as electric vehicles and energy storage systems (ESS). In particular, for medium and large devices, a battery module can be provided that includes a plurality of prismatic battery cells electrically connected to each other to enhance the output and / or capacity of the battery.

[0004] Such a battery module may include a plurality of battery cells, a plurality of busbars connecting the respective cell terminals of the plurality of battery cells, a busbar holder supporting the plurality of busbars, and side plates facing the respective side surfaces of the plurality of battery cells.

[0005] The foregoing information disclosed in this background art section provides only an enhanced understanding of the background art of the present disclosure and may therefore include information that does not constitute related art. Summary of the Invention

[0006] Aspects of the present invention provide a battery module including a busbar assembly and a method for manufacturing the battery module, the busbar assembly including a busbar, a support film supporting the busbar, and a support plate supporting the support film.

[0007] These and other aspects and features of the present disclosure will be described in the following description of some embodiments of the present disclosure or will be apparent from the following description of some embodiments of the present disclosure.

[0008] According to one aspect of the present invention, a battery module includes: a plurality of battery cells arranged in a first direction and each including a cell housing and a cell terminal protruding from the cell housing; and a busbar assembly including a busbar, a support film, and a support plate, the busbar allowing electrical connection between the respective cell terminals of at least a pair of the plurality of battery cells, the support film being bonded to the busbar to support the busbar, and the support plate being bonded to the support film to support the support film.

[0009] The support film may include a first film layer for the busbar assembly and a second film layer for the busbar assembly, wherein the second film layer is disposed above the first film layer and positioned farther from the plurality of battery cells than the first film layer.

[0010] The bus bar and the support plate can be disposed between the first film layer and the second film layer.

[0011] The first film layer can be thermally bonded to the second film layer, and the bus bar and the support plate can be bonded to the support film through the bonding between the first film layer and the second film layer.

[0012] The support plate can be formed with a bus bar window such that the support plate does not cover the bus bar.

[0013] The first film layer can be formed with a cell terminal contact window having an opening to allow contact between the bus bar and the cell terminal.

[0014] The second film layer can be formed with a welding window having an opening to allow energy for welding the bus bar to the cell terminal to be transferred through the second film layer to the bus bar.

[0015] The bus bar can be formed with a bus bar guide pin hole, and the bus bar guide pin is assembled into the bus bar guide pin hole to guide the position of the bus bar relative to the support plate and the support film.

[0016] Each battery cell can include a pair of cell terminals, wherein the pair of cell terminals can protrude from the cell housing in directions opposite to each other and intersecting the direction in which a plurality of battery cells are arranged.

[0017] The bus bar assembly can include a pair of bus bar assemblies, wherein the pair of bus bar assemblies can cover the cell terminals and can be spaced apart from each other with a plurality of battery cells arranged between the pair of bus bar assemblies.

[0018] The bus bar can include: a first joint portion joined to the cell terminal of one of the plurality of battery cells; a second joint portion joined to the cell terminal of another one of the plurality of battery cells; and an intermediate portion electrically connecting the first joint portion to the second joint portion and deforming prior to the first joint portion and the second joint portion when an external force is applied to the bus bar.

[0019] The battery module can further include an end plate assembly covering the outermost battery cell among the plurality of battery cells, wherein the end plate assembly can include: a plurality of plate members spaced apart from each other; a first film layer for the end plate assembly supporting the plurality of plate members; and a second film layer for the end plate assembly disposed above the first film layer and joined to the first film layer with the plurality of plate members disposed between the first film layer and the second film layer.

[0020] According to another aspect of the present invention, a method for manufacturing a battery module includes the following steps: manufacturing a bus bar assembly, the bus bar assembly including a bus bar, a support film bonded to the bus bar to support the bus bar, and a support plate bonded to the support film to support the support film; arranging a plurality of battery cells each including a cell housing and a cell terminal protruding from the cell housing such that the cell terminals face the bus bar; and bonding the bus bar to the cell terminals.

[0021] The support film may include: a first film layer for the bus bar assembly and a second film layer for the bus bar assembly, the second film layer being disposed above the first film layer, and the bus bar and the support plate may be disposed between the first film layer and the second film layer.

[0022] The step of manufacturing the bus bar assembly may include: a first film layer setting step in which the first film layer is placed on a jig for the bus bar assembly; a bus bar setting step in which the bus bar is placed on the first film layer; a support plate setting step in which the support plate is placed on the first film layer; a second film layer setting step in which the second film layer is placed on the jig to cover the first film layer, the bus bar, and the support plate; and a film layer bonding step in which the first film layer is bonded to the second film layer to form a support film to which the bus bar and the support plate are bonded.

[0023] The first film layer may extend in a direction along which the plurality of battery cells are arranged, and the jig may include: a first guide pin that blocks a longitudinal end of the first film layer in the first film layer setting step to prevent the first film layer from sliding relative to the jig in the longitudinal direction of the first film layer; and a second guide pin that blocks a lateral end of the first film layer in the first film layer setting step to prevent the first film layer from sliding relative to the jig in the lateral direction of the first film layer.

[0024] The support plate may extend in a direction along which the plurality of battery cells are arranged, and the jig may further include: a third guide pin spaced apart from the first film layer and blocking a longitudinal end of the support plate in the support plate setting step to prevent the support plate from sliding relative to the jig in the longitudinal direction of the support plate; and a fourth guide pin spaced apart from the first film layer and blocking a lateral end of the support plate in the support plate setting step to prevent the support plate from sliding relative to the jig in the lateral direction of the support plate.

[0025] The bus bar may be formed with a bus bar guide pin hole, and the jig may further include: a bus bar guide pin assembled into the bus bar guide pin hole and passing through both the first film layer and the second film layer to allow the bus bar to be locked in position relative to the jig in the bus bar setting step.

[0026] The method may further include the following steps: manufacturing an end plate assembly including a plurality of plate members spaced apart from each other, a first film layer for the end plate assembly, and a second film layer for the end plate assembly, the first film layer supporting the plurality of plate members, the second film layer being disposed over the first film layer and joined to the first film layer with the plurality of plate members positioned between the first film layer and the second film layer; and joining the end plate assembly to a bus bar assembly.

[0027] The step of manufacturing the end plate assembly may include: a first film layer setting step in which the first film layer is placed on a fixture for the end plate assembly; a plate member setting step in which the plurality of plate members are placed on the first film layer; a second film layer setting step in which the second film layer is placed on the fixture to cover the first film layer and the plurality of plate members; and a film layer joining step in which the first film layer is joined to the second film layer to join the plurality of plate members to the first film layer and the second film layer.

[0028] According to an embodiment of the present invention, a battery module includes a bus bar assembly including a bus bar, a support film supporting the bus bar, and a support plate supporting the support film. Accordingly, a bus bar holder made of metal for supporting the bus bar can be excluded, thereby reducing associated costs, improving component productivity, and enabling the battery module to be miniaturized and lightweight.

[0029] By using a flexible support film for supporting the bus bar, the tolerance for joining the bus bar to a cell terminal between the bus bar and the cell terminal can be increased. As a result, welding failures between the bus bar and the cell terminal can be reduced, and the yield of high-quality battery module products can be improved.

[0030] However, aspects and features of the present invention are not limited to the above aspects and features, and other aspects and features not mentioned will be clearly understood by those skilled in the art from the detailed description given below. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The drawings attached to this specification illustrate embodiments of the present invention and further describe aspects and features of the present invention together with the detailed description of the present invention. However, the present invention should not be construed as being limited to the drawings:

[0032] Figure 1 is a perspective view of a battery module according to a first embodiment of the present invention;

[0033] Figure 2 is Figure 1 a perspective view of a plurality of battery cells;

[0034] Figure 3 is Figure 1 an external perspective view of the bus bar assembly;

[0035] Figure 4 is Figure 1 an internal perspective view of the bus bar assembly of

[0036] Figure 5 is Figure 3 a top-down exploded perspective view of the bus bar assembly of

[0037] Figure 6 is Figure 3 a bottom-up exploded perspective view of the bus bar assembly of

[0038] Figure 7 is Figure 5 a plan view of the bus bar of

[0039] Figure 8 a perspective view of a battery module according to a second embodiment of the present invention;

[0040] Figure 9 is Figure 8 an internal perspective view of the end plate assembly of

[0041] Figure 10 is Figure 8 a top-down exploded perspective view of the end plate assembly of

[0042] Figure 11 is Figure 8 a bottom-up exploded perspective view of the end plate assembly of

[0043] Figure 12 a flowchart of a method for manufacturing a battery module according to an embodiment of the present invention;

[0044] Figure 13 is Figure 12 a flowchart of an embodiment of the manufacturing steps of the bus bar assembly in

[0045] Figure 14 is Figure 12 a perspective view of an example of a fixture used in the manufacturing steps of the bus bar assembly in

[0046] Figure 15 is Figure 14 a perspective view of a fixture on which the first film layer used for the bus bar assembly is placed;

[0047] Figure 16 is Figure 15 an enlarged plan view of region XVI of

[0048] Figure 17 is Figure 14 a perspective view of a fixture on which the first film layer, the bus bar, and the support plate used for the bus bar assembly are placed;

[0049] Figure 18 isFigure 17 Enlarged plan view of part XVIII;

[0050] Figure 19 is Figure 14 Perspective view of a jig on which a first film layer for a bus bar assembly, a bus bar, a support plate, and a second film layer for the bus bar assembly are placed;

[0051] Figure 20 is Figure 19 Perspective view of a jig in which a first film layer for a bus bar assembly is thermally bonded to a second film layer for the bus bar assembly;

[0052] Figure 21 is Figure 12 Flow chart of an embodiment of the end plate assembly manufacturing steps in;

[0053] Figure 22 is in Figure 21 Perspective view of a jig used in the end plate assembly manufacturing steps;

[0054] Figure 23 is Figure 22 Plan view of a jig on which a first film layer for an end plate assembly is placed;

[0055] Figure 24 is Figure 22 Plan view of a jig on which a first film layer for an end plate assembly and an end plate are placed;

[0056] Figure 25 is Figure 22 Plan view of a jig on which a first film layer for an end plate assembly, an end plate, and a second film layer for the end plate assembly are placed; and

[0057] Figure 26 is Figure 22 Plan view of a jig on which a first film layer for an end plate assembly and a second film layer for the end plate assembly are placed and thermally bonded to each other. Detailed Description of the Invention

[0058] Herein, some embodiments of the present disclosure will be further described in detail with reference to the accompanying drawings. The terms or words used in this specification and the claims will not be construed as limited to the ordinary meaning or the dictionary meaning, but should be construed as having a meaning and concept consistent with the technical concept of the present disclosure based on the principle that the inventor can be his / her own lexicographer to appropriately define the terms.

[0059] The embodiments described in this specification and the configurations shown in the drawings are provided as some example embodiments of the present disclosure and do not represent all of the technical ideas, aspects, and features of the present disclosure. Therefore, it will be understood that various equivalents and modifications that can replace or modify the embodiments described herein may exist at the time of filing this application.

[0060] It will be understood that when an element or layer is referred to as being "on", "connected to", or "coupled to" another element or layer, the element or layer can be directly on, directly connected to, or directly coupled to the other element or layer, or there may also be one or more intervening elements or layers. When an element or layer is referred to as being "directly on", "directly connected to", or "directly coupled to" another element or layer, there are no intervening elements or layers. For example, when a first element is described as being "coupled" or "connected" to a second element, the first element can be directly coupled or directly connected to the second element, or the first element can be indirectly coupled or indirectly connected to the second element via one or more intervening elements.

[0061] In the drawings, for clarity of illustration, the sizes of various elements, layers, etc. are exaggerated. The same reference numerals denote the same or similar elements. As used herein, the term "and / or" includes any combination and all combinations of one or more of the associated listed items. Further, when describing embodiments of the present disclosure, the use of "may" relates to "one or more embodiments of the present disclosure". Expressions such as "at least one of..." and "any one of..." modify the entire list of elements following the list and not individual elements in the list. When phrases such as "at least one of A, B, and C", "at least one of A, B, or C", "at least one selected from the group consisting of A, B, and C", or "at least one selected from among A, B, and C" are used to denote a list of elements A, B, and C, the phrase can refer to any and all suitable combinations or subsets of A, B, and C, such as A, B, C, A and B, A and C, B and C, or A and B and C. As used herein, the terms "use" and its variants can be considered to be synonymous with the terms "utilize" and its variants, respectively. As used herein, the terms "substantially", "about", and similar terms are used as approximate terms and not as terms of degree, and are intended to account for the inherent deviations of measured or calculated values that would be recognized by a person of ordinary skill in the art.

[0062] It will be understood that although the terms "first", "second", "third", etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, first component, first region, first layer or first section discussed below may be referred to as a second element, second component, second region, second layer or second section without departing from the teachings of the exemplary embodiments.

[0063] For ease of description, spatial relative terms such as "beneath", "below", "under", "above", "on", etc. may be used herein to describe the relationship of one element or feature to another (or other) element or feature as shown in the figures. It will be understood that the spatial relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, an element described as "beneath" or "under" another element or feature will be oriented "above" or "on" the other element or feature. Thus, the term "beneath" can encompass both an above and a below orientation. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and the spatial relative descriptors used herein should be interpreted accordingly.

[0064] The terms used herein are for the purpose of describing embodiments of the present disclosure and are not intended to limit the present disclosure. As used herein, unless the context clearly indicates otherwise, the singular forms "a" and "an" are also intended to include the plural forms. It will also be understood that when the terms "comprises", "comprising", and / or their variants are used in this specification, it is specified that there are the stated features, integers, steps, operations, elements, and / or components, but does not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0065] In addition, any numerical range recited herein is intended to include all sub-ranges having the same numerical precision contained within the recited range. For example, a range of "1.0 to 10.0" is intended to include all sub-ranges between the recited minimum value of 1.0 and the recited maximum value of 10.0 (and including the recited minimum value of 1.0 and the recited maximum value of 10.0), i.e., having a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as, for example, 2.4 to 7.6. Any maximum numerical limit recited herein is intended to include all lower numerical limits contained therein, and any minimum numerical limit recited in this specification is intended to include all higher numerical limits contained therein. Accordingly, the applicant reserves the right to amend this specification and the claims to expressly recite any sub-ranges that are included within the ranges expressly recited herein.

[0066] Two compared elements, features, etc. being referred to as "identical" can mean that they are substantially the same. Thus, the phrase "identical" or "substantially the same" can include cases having a deviation considered low in the art, for example, a deviation of 5% or less. Additionally, when a certain parameter is said to be uniform in a given region, this can mean uniform in terms of the average value.

[0067] Throughout the specification, unless otherwise stated, each element can be single or multiple.

[0068] When any element is referred to as being disposed "above (or below)" or "on (or under)" a component, this can mean that the any element is placed in contact with the upper (or lower) surface of the component, or it can mean that another component can be disposed between the component and the any element disposed "above (or below)" or "on (or under)" the component.

[0069] Furthermore, it will be understood that when an element is referred to as being "coupled", "linked", or "connected" to another element, these elements can be directly "coupled", "linked", or "connected" to each other, or there can be one or more intervening elements between the two, through which the element can be "coupled", "linked", or "connected" to the other element. Additionally, when a component is referred to as being "electrically coupled" to another component, the component can be directly electrically connected to the other component, or there can be one or more intervening components therebetween such that the component and the other component are indirectly electrically connected to each other.

[0070] Throughout the specification, unless otherwise stated, when stating "A and / or B", it means A, B, or A and B. That is, "and / or" includes any combination or all combinations of the listed multiple items. Unless otherwise stated, when stating "C to D", it means C or greater and D or less.

[0071] The terms used in this specification are for the purpose of describing embodiments of the present disclosure and are not intended to limit the present disclosure.

[0072] Figure 1 is a perspective view of a battery module according to a first embodiment of the present invention; Figure 2 is Figure 1 a perspective view of a plurality of battery cells of Figure 3 is Figure 1 an external perspective view of the bus bar assembly of Figure 4 is Figure 1 an internal perspective view of the bus bar assembly of Figure 5 is Figure 3 a top-down exploded perspective view of the bus bar assembly of Figure 6 is Figure 3 a bottom-up exploded perspective view of the bus bar assembly of Figure 7 is Figure 5 a plan view of the bus bar of

[0073] Referring to Figures 1 to 7 , the battery module 100 according to the first embodiment of the present invention includes a plurality of battery cells 101 and a bus bar assembly 200. The plurality of battery cells 101 are arranged in one direction. Here, the one direction may be a first direction.

[0074] The battery cell 101 is a rechargeable / dischargeable secondary battery cell and includes a cell housing 102 and cell terminals 110, 111. The battery cell 101 may be a so-called "side-type prismatic battery cell", wherein a pair of cell terminals 110, 111 (i.e., a negative cell terminal 110 and a positive cell terminal 111) joined to the bus bars 260, 273 are respectively provided on opposite sides of the cell housing 102.

[0075] The cell housing 102 may be formed of a metallic material such as, for example, aluminum alloy and may have a generally cubic shape. The cell housing 102 may include: a cell can having a pair of openings formed at opposite sides of the cell can in a second direction orthogonal to the first direction; and a pair of cover plates closing the pair of openings of the cell can. The negative cell terminal 110 may protrude from one of the pair of cover plates, and the positive cell terminal 111 may protrude from the other of the pair of cover plates.

[0076] An electrode assembly (not shown) may be accommodated in the cell housing 102. The electrode assembly may be formed by winding or stacking a stack of a first electrode plate, a separator, and a second electrode plate each formed as a thin plate or film.

[0077] When the electrode assembly is a wound stack, the winding axis may be parallel to the longitudinal direction of the single cell housing 102. Here, the longitudinal direction of the single cell housing 102 may be parallel to the second direction. However, the shape of the electrode assembly is not particularly limited in the present invention, and the electrode assembly may be a stacked electrode assembly instead of a wound electrode assembly.

[0078] The electrode assembly may be a Z-stack electrode assembly in which a positive electrode plate and a negative electrode plate are inserted into opposite sides of a separator bent in a "Z" shape. In addition, one or more electrode assemblies stacked on one another with their long sides adjacent to each other may be accommodated in the single cell housing. However, the number of electrode assemblies is not particularly limited in the present invention. The first electrode plate of the electrode assembly may serve as the negative electrode, and the second electrode plate of the electrode assembly may serve as the positive electrode. Of course, the reverse is also possible.

[0079] The first electrode plate may be formed by applying a first electrode active material such as graphite or carbon to a first electrode current collector plate formed of a metal foil such as copper, copper alloy, nickel, or nickel alloy, and may include a first electrode tab (or first uncoated portion) as an area where the first electrode active material is not coated. The first electrode tab may provide a path for current to flow between the first electrode plate and the first current collector. In some embodiments, the first electrode tab may be formed by pre-cutting the first electrode plate during the manufacture of the first electrode plate such that a portion of the first electrode plate protrudes beyond the separator from one side of the electrode assembly without additional cutting.

[0080] The second electrode plate may be formed by applying a second electrode active material such as a transition metal oxide to a second electrode current collector plate formed of a metal foil such as aluminum or aluminum alloy, and may include a second electrode tab (or second uncoated portion) as an area where the second electrode active material is not coated. The second electrode tab may provide a path for current to flow between the second electrode plate and the second current collector. In some embodiments, the second electrode tab may be formed by pre-cutting the second electrode plate during the manufacture of the second electrode plate such that a portion of the second electrode plate protrudes beyond the separator from the other side (e.g., the opposite side) of the electrode assembly without additional cutting.

[0081] The first electrode tab may be electrically connected to the negative electrode single cell terminal 110 inside the single cell housing 102, and the second electrode tab may be electrically connected to the positive electrode single cell terminal 111 inside the single cell housing 102.

[0082] The single cell housing 102 may include a pair of first surfaces 103, a pair of second surfaces 105, and a pair of third surfaces 107. The pair of first surfaces 103 are a pair of flat surfaces that are orthogonal to the first direction and spaced apart from each other. The pair of second surfaces 105 are a pair of flat surfaces that are orthogonal to the second direction and spaced apart from each other. The pair of third surfaces 107 are a pair of flat surfaces that are orthogonal to the third direction and spaced apart from each other. Herein, the third direction is defined as the direction orthogonal to the first direction and the second direction.

[0083] The pair of first surfaces 103, the pair of second surfaces 105, and the pair of third surfaces 107 may define an internal space of the single cell housing 102 in which the electrode assembly is received. A pair of single cell terminals 110, 111 may protrude from the pair of second surfaces 105 in the second direction, respectively. The pair of single cell terminals 110, 111 of one single cell 101 may protrude in opposite directions. The negative single cell terminal 110 and the positive single cell terminal 111 may be alternately arranged in the first direction.

[0084] The third surface 107 may be provided with a single cell vent 109. The single cell vent 109 may rupture when hot gas and combustion debris are generated inside the single cell housing 102 due to overcharging, abnormal operation, etc., to allow emissions including hot gas, combustion debris, etc. to be discharged from the single cell housing 102 through it.

[0085] For example, the first direction is the direction along which a plurality of single cells 101 are arranged in a row, and may be the forward / backward direction of the battery module 100. The second direction is the direction orthogonal to the first direction, and may be the right / left direction of the battery module 100. Additionally, the second direction may be the longitudinal direction of the single cell 101 or the single cell housing 102. The third direction is the direction orthogonal to the first direction and the second direction, and may be the up / down direction of the battery module 100.

[0086] The bus bar assembly 200 includes bus bars 260, 273, 276, a support film 201, and a support plate 250. The battery module 100 may include a pair of bus bar assemblies 200. The pair of bus bar assemblies 200 may be spaced apart from each other by a plurality of single cells 101 arranged therebetween, and may cover the plurality of single cell terminals 110, 111.

[0087] Specifically, one of the pair of bus bar assemblies 200 may face the plurality of single cell terminals 110, 111 arranged on the left side of the plurality of single cells 101, and the other of the pair of bus bar assemblies 200 may face the plurality of single cell terminals 110, 111 arranged on the right side of the plurality of single cells 101.

[0088] The bus bars 260, 273, 276 may include an inter-cell bus bar 260, an intermediate bus bar 273, and an inter-module bus bar 276. The inter-cell bus bar 260 may electrically connect one cell terminal 110 or 111 of one of a pair of adjacent cell units 101 among a plurality of cell units 101 to one cell terminal 111 or 110 of the other of the pair of adjacent cell units 101.

[0089] The inter-cell bus bar 260 may include a first joint portion 261, a second joint portion 263, and an intermediate portion 265. The inter-cell bus bar 260 may be a plate-like member formed of metal. The first joint portion 261, the second joint portion 263, and the intermediate portion 265 may be integrally formed with each other.

[0090] The first joint portion 261 may be joined to one cell terminal 110 or 111 of one of the plurality of cell units 101. The second joint portion 263 may be joined to one cell terminal 111 or 110 of another cell unit 101 adjacent to the one cell unit 101. The cell terminal 110 or 111 joined to the first joint portion 261 may be adjacent to the cell terminal 111 or 110 joined to the second joint portion 263 in a first direction.

[0091] The intermediate portion 265 may electrically connect the first joint portion 261 to the second joint portion 263. When an external force is applied to the inter-cell bus bar 260, the intermediate portion 265 may be deformed before the first joint portion 261 and the second joint portion 263 are deformed. For example, the intermediate portion 265 may have a slit 267 formed therethrough in its thickness direction and extending in one direction. For example, the slit 267 may extend in a third direction. However, even without the slit 267, the intermediate portion 265 may be deformed prior to the first joint portion 261 and the second joint portion 263 because it has a thickness smaller than the thicknesses of both the first joint portion 261 and the second joint portion 263.

[0092] As a result, even when the cell terminal 110 or 111 joined to the first joint portion 261 has a coordinate position different from that of the cell terminal 111 or 110 joined to the second joint portion 263 in a second direction, the intermediate portion 265 may be bent so that each of the first joint portion 261 and the second joint portion 263 is in close contact with the corresponding one of the cell terminals 110, 111, minimizing internal stress therein.

[0093] The length of the first joint portion 261 in a third direction may be greater than the length of the second joint portion 263. The first joint portion 261 may be connected to a sensor at its end in the third direction, and the sensor detects and measures values representing the state of the battery module 100, such as voltage or temperature, during charging / discharging of the battery module 100.

[0094] The planar area of the inter-cell bus bar 260 can be four to five times the planar area of one of the cell terminals 110 or 111 joined to the inter-cell bus bar 260. If the planar area of the inter-cell bus bar 260 is less than four times the planar area of the cell terminal 110 or 111, the inter-cell bus bar 260 will overheat during high-voltage charging / discharging. If the planar area of the inter-cell bus bar 260 exceeds five times the planar area of the cell terminal 110 or 111, the battery module 100 will be unnecessarily heavy and / or the manufacturing cost will increase.

[0095] A plurality of battery modules 100 can be incorporated into a battery pack (not shown). The inter-module bus bar 276 can electrically connect one battery module 100 in the battery pack to another adjacent battery module 100, or can electrically connect the battery module 100 to a battery pack control unit (not shown).

[0096] The intermediate bus bar 273 electrically connects one of the plurality of battery cells 101 in the battery module 100 to the inter-module bus bar 276. The intermediate bus bar 273 can have the shape of a generally rectangular plate. The intermediate bus bar 273 can be joined to the cell terminals 110, 111 at one of its sides and can be joined to the inter-module bus bar 276 at the other of its sides.

[0097] The support film 201 is bonded to the inter-cell bus bar 260 to support the inter-cell bus bar 260. The support film 201 can also support the intermediate bus bar 273 and the plurality of inter-cell bus bars 260. The support plate 250 is bonded to the support film 201 to support the support film 201.

[0098] The support film 201 can include a first film layer 210 for the bus bar assembly 200 and a second film layer 230 for the bus bar assembly 200, wherein the second film layer 230 for the bus bar assembly 200 is disposed above the first film layer 210 for the bus bar assembly 200 and is positioned farther from the plurality of battery cells 101 than the first film layer 210 for the bus bar assembly 200. The first film layer 210 for the bus bar assembly 200 and the second film layer 230 for the bus bar assembly 200 can be formed of, for example, polyethylene terephthalate (PET). The plurality of inter-cell bus bars 260, one intermediate bus bar 273, and one support plate 250 can be placed between the first film layer 210 for the bus bar assembly 200 and the second film layer 230 for the bus bar assembly 200.

[0099] The support plate 250 can be formed of, for example, a metallic material such as aluminum alloy. The support plate 250 can include a rectangular frame 251 and flanges 257. The rectangular frame 251 can have the shape of a generally rectangular plate and can be formed with a bus bar window 258 at its center. A plurality of inter-cell bus bars 260 and an intermediate bus bar 273 can be disposed in the area opened by the bus bar window 258 such that the support plate 250 does not cover or overlap with the bus bars 260, 273.

[0100] The flanges 257 can protrude from the rectangular frame 251 in a second direction and can extend in a first direction. The flanges 257 can be coupled and fixed to a housing (not shown) of a battery pack (not shown).

[0101] The first film layer 210 for the bus bar assembly 200 can be formed with a plurality of cell terminal contact windows 211 that open to establish contact between a plurality of cell terminals 110, 111 and the bus bars 260, 273 (e.g., a plurality of inter-cell bus bars 260 and one intermediate bus bar 273). The plurality of cell terminal contact windows 211 can be spaced apart from each other in the first direction.

[0102] The second film layer 230 for the bus bar assembly 200 can be formed with a plurality of welding windows 231, 233, 235. The plurality of welding windows 231, 233, and 235 can include a first welding window 231, a second welding window 233, and a third welding window 235. The first welding window 231 allows energy for welding one first joint 261 to one of the cell terminals 110 or 111 to be transferred across the second film layer 230 for the bus bar assembly 200 to the one first joint 261.

[0103] The second welding window 233 allows energy for welding one second joint 263 to one of the cell terminals 111 or 110 to be transferred across the second film layer 230 for the bus bar assembly 200 to the one second joint 263. The first welding window 231 allows energy for welding a sensor (not shown) for detecting the state of the battery module 100 to the sensor joint 262 to be transferred across the second film layer 230 for the bus bar assembly 200 to this sensor joint 262. The first joint 261 has a greater length than the second joint 263, and the first welding window 231 can have a greater length than the second welding window 233.

[0104] For example, laser welding can be used for welding between the inter-cell bus bars 260 and the cell terminals 110, 111, between the intermediate bus bar 273 and the cell terminals 110, 111, and between the intermediate bus bar 273 and the inter-module bus bar 276. However, the present invention is not limited thereto, and various other welding techniques such as ultrasonic welding or resistance welding can be used.

[0105] The first film layer 210 for the bus bar assembly 200 and the second film layer 230 for the bus bar assembly 200 can be joined to each other by hot pressing. The plurality of inter - monomer bus bars 260, the intermediate bus bar 273, and the support plate 250 can be joined to the support film 201 by the joining between the first film layer 210 for the bus bar assembly 200 and the second film layer 230 for the bus bar assembly 200.

[0106] For example, the first film layer 210 for the bus bar assembly 200 can be formed with an outer bus bar joint 213 in the region where it surrounds the inter - monomer bus bar 260 and the intermediate bus bar 273, and the second film layer 230 for the bus bar assembly 200 can have an outer bus bar joint 237 in the region where it surrounds the inter - monomer bus bar 260 and the intermediate bus bar 273, wherein the outer bus bar joints 213, 237 are joined to each other by hot pressing.

[0107] Since the plurality of inter - monomer bus bars 260 and the intermediate bus bar 273 are surrounded by the outer bus bar joints 213, 237, it is possible to prevent the plurality of inter - monomer bus bars 260 and the intermediate bus bar 273 from separating or detaching from the support film 201, or it is possible to prevent the plurality of inter - monomer bus bars 260 and the intermediate bus bar 273 from being misaligned or in an improper position on the support film 201.

[0108] Each of the first film layer 210 for the bus bar assembly 200 and the second film layer 230 for the bus bar assembly 200 can have a generally rectangular planar shape and can have the same dimensions. The first film layer 210 for the bus bar assembly 200 and the second film layer 230 for the bus bar assembly 200 can extend in a first direction. The distance LF (see Figure 15 ) between the opposite longitudinal ends 218 of the first film layer 210 for the bus bar assembly 200 and the distance between the opposite longitudinal ends 243 of the second film layer 230 for the bus bar assembly 200 can each be equal to the length of the support film 201. That is, the length LF of the first film layer 210 for the bus bar assembly 200, the length of the second film layer 230 for the bus bar assembly 200, and the length of the support film 201 can be equal to each other.

[0109] The distance WF (see Figure 16) and the distance between the opposite transverse ends 244 of the second film layer 230 for the bus bar assembly 200 can each be equal to the width of the support film 201. That is, the width WF of the first film layer 210 for the bus bar assembly 200, the width of the second film layer 230 for the bus bar assembly 200, and the width of the support film 201 can be equal to each other. Here, the transverse direction of each of the first film layer 210 and the second film layer 230 for the bus bar assembly 200 can correspond to the third direction.

[0110] The rectangular frame 251 of the support plate 250 extends in the first direction. The distance LP between the opposite longitudinal ends 252 of the support plate 250 (see Figure 17 ), that is, the length LP of the support plate 250 can be greater than the length LF of the support film 201. The distance WP between the opposite transverse ends 254 of the rectangular frame 251 (see Figure 18 ), that is, the width WP of the support plate 250 can be less than the width WF of the support film 201.

[0111] Since the width WF of the support film 201 is greater than the width WP of the support plate 250, the first film layer 210 for the bus bar assembly 200 can be formed with a peripheral joint 216 formed in the region near the transverse end 219 of the first film layer 210, and the second film layer 230 for the bus bar assembly 200 can be formed with a peripheral joint 239 formed in the region near the transverse end 244 of the second film layer 230, wherein the peripheral joints 216, 239 can be joined to each other by hot pressing. The first film layer 210 for the bus bar assembly 200 can have a support plate contact portion 217 formed between the peripheral bus bar joint 213 and the peripheral joint 216 and in face-to-face contact with the rectangular frame 251. The second film layer 230 for the bus bar assembly 200 can have a support plate contact portion 241 formed between the peripheral bus bar joint 237 and the peripheral joint 239 and in face-to-face contact with the rectangular frame 251.

[0112] Since the rectangular frame 251 of the support plate 250 is surrounded by the peripheral bus bar joints 213, 237 and the peripheral joints 216, 239, separation or detachment of the support plate 250 from the support film 201 can be prevented, or misalignment or improper positioning of the support plate 250 on the support film 201 can be prevented. The second film layer 230 for the bus bar assembly 200 can be formed with a flange penetration slit 247 through which the flange 257 of the support plate 250 passes.

[0113] The battery module 100 can further include a pair of end plates 120. The pair of end plates 120 can be spaced apart from each other to cover the frontmost battery cell 101 and the rearmost battery cell 101 among the plurality of battery cells 101 arranged in the first direction.

[0114] The respective left ends of a pair of end plates 120 can be joined and fixed to the opposite longitudinal ends 252 of a support plate 250 of a left bus bar assembly 200 among a pair of bus bar assemblies 200, and the respective right ends of the pair of end plates 120 can be joined and fixed to the opposite longitudinal ends 252 of a support plate 250 of a right bus bar assembly 200 among the pair of bus bar assemblies 200.

[0115] As described above, the battery module 100 includes a bus bar assembly 200, and the bus bar assembly 200 includes bus bars 260, 273, a support film 201 that supports the bus bars 260, 273, and a support plate 250 that supports the support film 201. As a result, the use of a bus bar holder formed of metal for supporting the bus bars 260, 273 can be eliminated, thereby reducing the associated costs, improving the component productivity, and enabling the battery module 100 to be miniaturized and lightweight.

[0116] In addition, by using the flexible support film 201 that supports the bus bars 260, 273, the tolerance for joining the bus bars 260, 273 to the cell terminals 110, 111 can be increased between the bus bars 260, 273 and the cell terminals 110, 111. As a result, the welding failures between the bus bars 260, 273 and the cell terminals 110, 111 can be reduced, and the yield of high-quality battery module products can be improved.

[0117] Figure 8 is a perspective view of a battery module according to a second embodiment of the present invention; Figure 9 is Figure 8 an internal perspective view of an end plate assembly of Figure 10 is Figure 8 a top exploded perspective view of an end plate assembly of Figure 11 is Figure 8 a bottom exploded perspective view of an end plate assembly of

[0118] Referring to Figures 8 to 11 According to a second embodiment of the present invention, a battery module 300 includes a plurality of battery cells 101, a bus bar assembly 200, and an end plate assembly 301. Since the plurality of battery cells 101 and the bus bar assembly 200 are the same as those of the battery module 100 according to the first embodiment, their repeated descriptions will be omitted.

[0119] The end plate assembly 301 covers the outermost battery cell 101 among the plurality of battery cells 101. For example, the end plate assembly 301 may include a pair of end plate assemblies. The pair of end plate assemblies 301 may be spaced apart from each other to cover the foremost battery cell 101 and the rearmost battery cell 101 among the plurality of battery cells 101 arranged in a first direction.

[0120] The respective left ends of a pair of end plate assemblies 301 may be coupled and fixed to the opposite longitudinal ends 252 of a support plate 250 of a left bus bar assembly 200 among a pair of bus bar assemblies 200, and the respective right ends of the pair of end plate assemblies 301 may be coupled and fixed to the opposite longitudinal ends 252 of a support plate 250 of a right bus bar assembly 200 among the pair of bus bar assemblies 200.

[0121] Each of the pair of end plate assemblies 301 may include a plurality of plate members 330, 340, 350, a first film layer 302 for the end plate assembly 301, and a second film layer 312 for the end plate assembly 301. For example, each of the pair of end plate assemblies 301 may include three plate members 330, 340, 350.

[0122] Among the plurality of plate members 330, 340, 350, the first plate member 330 may be disposed at the topmost, the third plate member 350 may be disposed at the lowermost, and the second plate member 340 may be disposed between the first plate member 330 and the third plate member 350. The plurality of plate members 330, 340, 350 may be spaced apart from each other.

[0123] Each of the plurality of plate members 330, 340, 350 may include a base portion 331, 341, 351 extending in a second direction and a pair of bent portions 334, 344, 354 bent from opposite longitudinal ends of the base portions 331, 341, 351 to protrude in a first direction. The pair of bent portions 334, 344, 354 may be coupled to respective ends 255 of a pair of support plates 250 in the first direction.

[0124] The base portions 331, 341, 351 may be formed with ribs 332, 342, 352 to enhance rigidity. The third plate member 350 may further include a flange portion 356 protruding in the first direction from the base portion 351.

[0125] The first film layer 302 for the end plate assembly 301 may support the plurality of plate members 330, 340, 350. The second film layer 312 for the end plate assembly 301 may be disposed on the first film layer 302 for the end plate assembly 301 and joined to the first film layer 302 for the end plate assembly 301, and place the plurality of plate members 330, 340, 350 between the second film layer 312 for the end plate assembly 301 and the first film layer 302 for the end plate assembly 301.

[0126] The first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301, which are disposed on top of each other and joined to each other, form a support film for the end plate assembly that supports a plurality of plate members 330, 340, 350. Each of the first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301 can be formed of, for example, polyethylene terephthalate (PET).

[0127] The first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301 can be joined to each other by hot pressing. The plurality of plate members 330, 340, 350 can be joined to the support film for the end plate assembly by the joining between the first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301.

[0128] For example, the first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301 can be formed with respective intermediate joining portions 305, 315 that are joined to each other by hot pressing, where the joining portions 305, 315 are respectively disposed between the first plate member 330 and the second plate member 340 and between the second plate member 340 and the third plate member 350.

[0129] Each of the first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301 can have a generally rectangular planar shape and can have the same dimensions. The first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301 can extend in a second direction.

[0130] Since the width of each of the first film layer 302 for the end plate assembly 301 and the second film layer 312 for the end plate assembly 301 (i.e., the distance between its opposite ends in a third direction) is greater than the distance between the upper end of the base portion 331 of the first plate member 330 in the third direction and the lower end of the base portion 351 of the third plate member 350 in the third direction, the first film layer 302 for the end plate assembly 301 can be formed with a peripheral joining portion 307 in a region near its end in the third direction, and the second film layer 312 for the end plate assembly 301 can be formed with a peripheral joining portion 317 in a region near its end in the third direction (see Figure 25 ), where the peripheral joining portions 307, 317 can be joined to each other by hot pressing.

[0131] The first film layer 302 for the end plate assembly 301 may be formed with a plate contact portion 303 that makes face-to-face contact with the base portions 331, 341, 351 of the plates 330, 340, 350, and the second film layer 312 for the end plate assembly 301 may be formed with a plate contact portion 313 that makes face-to-face contact with the base portions 331, 341, 351 of the plates 330, 340, 350 (see Figure 26 ). In addition, the second film layer 312 for the end plate assembly 301 may be formed with a flange penetration slit 321 through which the flange portion 356 of the third plate 350 passes.

[0132] In the case where a plurality of battery cells 101 (see Figure 1 ) expand during charging / discharging of the battery module 300, the end plate assembly 301 including the plurality of plates 330, 340, 350 can elastically deform to a relatively large extent, thereby preventing accidents such as internal fire or explosion of the battery cells 101. In other words, the reliability of the battery module 300 can be improved.

[0133] Figure 12 is a flowchart of a method for manufacturing a battery module according to an embodiment of the present invention; Figure 13 is Figure 12 a flowchart of an embodiment of the bus bar assembly manufacturing step in Figure 14 is Figure 12 a perspective view of an example of a jig used in the bus bar assembly manufacturing step in Figure 15 is Figure 14 a perspective view of a jig on which the first film layer for the bus bar assembly is placed; Figure 16 is Figure 15 an enlarged plan view of region XVI of Figure 17 is Figure 14 a perspective view of a jig on which the first film layer for the bus bar assembly, the bus bar, and the support plate are placed; Figure 18 is Figure 17 an enlarged plan view of part XVIII of

[0134] Figure 19 is Figure 14 a perspective view of a jig on which the first film layer for the bus bar assembly, the bus bar, the support plate, and the second film layer for the bus bar assembly are placed; Figure 20 is Figure 19 a perspective view of a jig for thermally pressing and bonding the first film layer for the bus bar assembly to the second film layer for the bus bar assembly.

[0135] Referring to Figure 12 and Figure 13, A method for manufacturing a battery module according to an embodiment of the present invention includes a bus bar assembly manufacturing step S100, a battery cell arrangement step S200, and a bus bar joining step S300. In the bus bar assembly manufacturing step S100, a bus bar assembly 200 including bus bars 260, 273, a support film 201 coupled to the bus bars 260, 273 to support the bus bars 260, 273, and a support plate 250 coupled to the support film 201 to support the support film 201 is manufactured. Since the bus bar assembly 200 has been described with reference to Figures 1 to 7 it, a repeated description thereof will be omitted.

[0136] The bus bar assembly manufacturing step S100 may include a first film layer setting step S110, a bus bar setting step S120, a support plate setting step S130, a second film layer setting step S140, and a film layer joining step S150. Referring to Figures 13 to 16 , in the first film layer setting step S110, a first film layer 210 for the bus bar assembly 200 is placed on a jig 10 for the bus bar assembly.

[0137] The jig 10 may include: a jig base 11 having a generally rectangular plate shape; and a first guide pin 15 and a second guide pin 17 each protruding upward from the jig base 11. The jig base 11 may extend in a first direction like the first film layer 210 for the bus bar assembly 200, the second film layer 230 for the bus bar assembly 200, and the support plate 250.

[0138] The first film layer 210 may be placed on the jig base 11. The first guide pin 15 may block a longitudinal end 218 of the first film layer 210 placed on the jig base 11 in the first film layer setting step S110 to prevent the first film layer 210 from sliding relative to the jig 10 in the longitudinal direction of the first film layer 210.

[0139] There may be four first guide pins 15. Among these first guide pins 15, a pair of first guide pins 15 blocks the front end 218 of the first film layer 210. The pair of first guide pins 15 blocking the front end 218 may be spaced apart from each other in a third direction. Another pair of first guide pins 15 blocks the rear end 218 of the first film layer 210. The pair of first guide pins 15 blocking the rear end 218 may be spaced apart from each other in the third direction.

[0140] The second guide pin 17 blocks a lateral end 219 of the first film layer 210 placed on the jig base 11 in the first film layer setting step S110 to prevent the first film layer 210 from sliding relative to the jig 10 in the lateral direction of the first film layer 210.

[0141] There may be four second guide pins 17. Among these second guide pins 17, a pair of second guide pins 17 blocks the lateral ends 219 of the first film layer 210 in the third direction. The pair of second guide pins 17 that blocks the lateral ends 219 of the first film layer 210 in the third direction may be spaced apart from each other in the first direction. Another pair of second guide pins 17 blocks the other ends 219 of the first film layer 210 in the third direction. The pair of second guide pins 17 that blocks the other ends of the first film layer 210 in the third direction may be spaced apart from each other in the first direction.

[0142] The distance LG1 between a pair of first guide pins 15 spaced apart from each other in the first direction may be slightly greater than the length LF of the first film layer 210. The distance WG2 between a pair of second guide pins 17 spaced apart from each other in the third direction may be slightly greater than the width WF of the first film layer 210. When the first film layer 210 is in place on the fixture base 11, the end 218 of the first film layer 210 in the first direction may contact the first guide pin 15, and the end 219 of the first film layer 210 in the third direction may contact the second guide pin 17.

[0143] The cross-section of the first guide pin 15 may have a circular shape, while the cross-section of the second guide pin 17 may have a rectangular shape or an elliptical shape with the major axis extending in the first direction. The upper ends of the first guide pin 15 and the second guide pin 17 may be tapered, so as to ensure that in the first film layer setting step S110, the first film layer 210 can smoothly fall onto the fixture base 11 while sliding relative to the upper ends of the first guide pin 15 and the second guide pin 17, and to ensure that in the second film layer setting step S140, the second film layer 230 can smoothly fall onto the fixture base 11 while sliding relative to the upper ends of the first guide pin 15 and the second guide pin 17.

[0144] Refer to Figure 7 、 Figure 13 、 Figure 17 and Figure 18 , in the bus bar setting step S120, the bus bars 260, 273 are placed on the first film layer 210. The bus bars 260, 273 placed on the first film layer 210 may include a plurality of inter-module bus bars 260 and one intermediate bus bar 273.

[0145] The fixture 10 may further include a plurality of bus bar guide pins 25, 27 protruding upward from the fixture base 11. The plurality of bus bar guide pins 25, 27 guide the positions of the bus bars 260, 273 relative to the support plate 250 and the support film 201.

[0146] A plurality of bus bar guiding pins 25, 27 may include: a plurality of inter-cell bus bar guiding pins 25, each assembled into a corresponding one of a plurality of inter-cell bus bars 260; and a pair of intermediate bus bar guiding pins 27, assembled into an intermediate bus bar 273.

[0147] The inter-cell bus bar 260 may be formed with inter-cell bus bar guiding pin holes 269, and a corresponding one of the plurality of inter-cell bus bar guiding pins 25 is assembled into the inter-cell bus bar guiding pin hole 269. An inter-cell bus bar guiding pin hole 269 may be formed at each of the first joint portion 261 and the second joint portion 263, away from the area of the inter-cell bus bar 260 that contacts the cell terminals 110, 111.

[0148] The intermediate bus bar 273 may be formed with a pair of intermediate bus bar guiding pin holes 274, and a pair of intermediate bus bar guiding pins 27 are inserted into the pair of intermediate bus bar guiding pin holes 274. The pair of intermediate bus bar guiding pin holes 274 may be formed to be spaced apart from each other and away from the area of the intermediate bus bar 273 that contacts the cell terminals 110, 111.

[0149] The bus bar guiding pins 25, 27 may be respectively assembled into the bus bar guiding pin holes 269, 274, and pass through the first film layer 210 and the second film layer 230, so that the bus bars 260, 273 can be locked in position relative to the fixture 10 in the bus bar setting step S120. In the first film layer setting step S110, each of the plurality of bus bar guiding pins 25, 27 may pass through the first film layer 210 through a corresponding one of the plurality of cell terminal contact windows 211.

[0150] When the inter-cell bus bar guiding pin 25 is assembled into the inter-cell bus bar guiding pin hole 269, and the intermediate bus bar guiding pin 27 is assembled into the intermediate bus bar guiding pin hole 274, the inter-cell bus bar 260 and the intermediate bus bar 273 may be located at appropriate positions on the fixture base 11.

[0151] The upper ends of the inter-cell bus bar guiding pin 25 and the intermediate bus bar guiding pin 27 may be tapered, so as to ensure that in the bus bar setting step S120, the inter-cell bus bar 260 and the intermediate bus bar 273 can smoothly fall onto the fixture base 11 while sliding relative to the upper ends of the inter-cell bus bar guiding pin 25 and the intermediate bus bar guiding pin 27.

[0152] In the support plate setting step S130, the support plate 250 is placed on the first film layer 210. The jig 10 further includes a third guide pin 20 and a fourth guide pin 22 each protruding upward from the jig base 11. The third guide pin 20 blocks the longitudinal end 252 of the support plate 250 in the support plate setting step S130 to prevent the support plate 250 from sliding relative to the jig 10 in the longitudinal direction of the support plate 250.

[0153] There may be a pair of third guide pins 20. The pair of third guide pins 20 may be spaced apart from the first film layer 210 placed on the jig base 11. The pair of third guide pins 20 is arranged to block the front end 252 and the rear end 252 of the support plate 250 in the first direction.

[0154] The fourth guide pin 22 blocks the lateral end 254 of the support plate 250 in the support plate setting step S130 to prevent the support plate 250 from sliding relative to the jig 10 in the lateral direction of the support plate 250.

[0155] There may be four fourth guide pins 22. The four fourth guide pins 22 may be spaced apart from the first film layer 210 placed on the jig base 11. Among the four fourth guide pins 22, a pair of fourth guide pins 22 may block one end 254 of the support plate 250 in the third direction.

[0156] Another pair of fourth guide pins 22 may block the other end 254 of the support plate 250 in the third direction. The four fourth guide pins 22 correspond one-to-one with the four first guide pins 15. Each fourth guide pin 22 may be adjacent to a corresponding one of the first guide pins 15.

[0157] The distance LG3 between a pair of third guide pins 20 spaced apart from each other in the first direction may be slightly larger than the length LP of the support plate 250. The distance WG4 between a pair of fourth guide pins 22 spaced apart from each other in the third direction may be equal to the distance WG1 between a pair of first guide pins 15 spaced apart from each other in the third direction, and may be slightly larger than the width WP of the support plate 250. The position of the third guide pin 20 in the third direction may be located in the middle between a pair of first guide pins 15 or a pair of fourth guide pins 22 spaced apart from each other in the third direction.

[0158] When the support plate 250 is at an appropriate position on the first film layer 210, the end 252 of the rectangular frame 251 in the first direction may contact the third guide pin 20, and the end of the rectangular frame 251 in the third direction may contact both the first guide pin 15 and the fourth guide pin 22. In addition, a plurality of inter-cell busbars 260 and an intermediate busbar 273 may be disposed in the region defined by the busbar window 258 without contacting the inner surface of the rectangular frame 251.

[0159] The cross-section of each of the third guide pin 20 and the fourth guide pin 22 may have a circular shape. The upper ends of the third guide pin 20 and the fourth guide pin 22 may be tapered, so as to ensure that, in the support plate setting step S130, the support plate 250 can smoothly fall onto the fixture base 11 while sliding relative to the upper ends of the third guide pin 20 and the fourth guide pin 22.

[0160] Although the bus bar setting step S120 is shown as being performed before the support plate setting step S130 in Figure 13 , this is merely illustrative, and the support plate setting step S130 may be performed before the bus bar setting step S120.

[0161] Referring to Figure 13 and Figure 19 , in the second film layer setting step S140, the second film layer 230 for the bus bar assembly 200 is placed on the fixture 10 to cover the first film layer 210, the bus bars 260, 273, and the support plate 250. The second film layer 230 may be formed with a plurality of bus bar guide pin holes 245 into which a plurality of inter-module bus bar guide pins 25 are assembled, and flange penetration slits 247 into which the flange 257 of the support plate 250 is assembled.

[0162] When the second film layer 230 is placed on the plurality of bus bars 260, 273, and the rectangular frame 251 such that the plurality of inter-module bus bar guide pins 25 are respectively assembled into the plurality of bus bar guide pin holes 245, and the flange 257 is assembled into the flange penetration slits 247, the second film layer 230 may be located at an appropriate position on the fixture 10. Here, a pair of intermediate bus bar guide pins 27 may pass through the second film layer 230 through the third welding window 235 of the second film layer 230.

[0163] Referring to Figure 13 and Figure 20 , in the film layer bonding step S150, the first film layer 210 is bonded to the second film layer 230 to form the support film 201 and to couple the bus bars 260, 273, and the support plate 250 to the support film 201. The film layer bonding step S150 may include a hot pressing step of heating the first film layer 210 and the second film layer 230 to melt and bond them together while pressing against each other.

[0164] As shown in Figure 20 , the hot pressing step may be performed by placing the first film layer 210, the second film layer 230, the support plate 250, and the plurality of bus bars 260, 273 on the fixture 10. Alternatively, the hot pressing step may be performed after removing the first film layer 210, the second film layer 230, the support plate 250, and the plurality of bus bars 260, 273 from the fixture 10.

[0165] Referring toFigure 1 , Figure 2 and Figure 12 , in the battery cell arrangement step S200, a plurality of battery cells 101 are arranged in one direction such that the cell terminals 110, 110 face the bus bars 260, 273. For example, a plurality of battery cells 101 can be arranged in the first direction such that the bus bars 260, 273 of the bus bar assembly 200 extending in the first direction face the cell terminals 110, 111 protruding from the second surface 105 of each of the plurality of battery cells 101.

[0166] In the bus bar joining step S300, the bus bars 260, 273 are joined to the cell terminals 110, 111. A plurality of bus bars 260, 273 can be joined to a plurality of cell terminals 110, 111. The bus bar joining step S300 can be performed by, for example, laser welding. The bus bar joining step S300 can include a bus bar pressing step and a laser irradiation step.

[0167] In the bus bar pressing step, the bus bar assembly 200 is moved closer to the plurality of battery cells 101 such that the bus bars 260, 273 are in close contact with the cell terminals 110, 111 through the cell terminal contact windows 211. In the laser irradiation step, a laser beam is applied to the surfaces of the bus bars 260, 273 exposed through the welding windows 231, 233, 235. In the laser irradiation step, the energy of the laser beam can locally melt and join the bus bars 260, 273 and the cell terminals 110, 111 together.

[0168] Since the battery module 100 includes a pair of bus bar assemblies 200, each of the battery cell arrangement step S200 and the bus bar joining step S300 can be performed once for each of the plurality of cell terminals 110, 111 arranged on the left side of the plurality of battery cells 101 in the first direction and the plurality of cell terminals 110, 111 arranged on the right side of the plurality of battery cells 101 in the first direction, that is, a total of two times can be performed.

[0169] The method for manufacturing a battery module according to the present invention may further include an inter-module bus bar joining step. In the inter-module bus bar joining step, the inter-module bus bar 276 can be joined to the intermediate bus bar 273 through the third welding window 235. The inter-module bus bar connection step can also be performed by laser welding like the bus bar joining step S300.

[0170] Referring to Figures 8 to 12 and Figures 21 to 26 , the method for manufacturing a battery module according to the present invention may further include an end plate assembly manufacturing step S400 and an end plate assembly combining step S500.

[0171] In the end plate assembly manufacturing step S400, an end plate assembly 301 is manufactured, which includes a plurality of plate members 330, 340, 350, a first film layer 302 for the end plate assembly 301, and a second film layer 312 for the end plate assembly 301. In the end plate assembly bonding step S500, the end plate assembly 301 is bonded to the bus bar assembly 200.

[0172] The end plate assembly manufacturing step S400 may include a first film layer setting step S510, a plate member setting step S520, a second film layer setting step S530, and a film layer bonding step S540.

[0173] Referring to Figures 21 to 23 , in the first film layer setting step S510, the first film layer 302 for the end plate assembly 301 is placed on the fixture 50 for the end plate assembly 301.

[0174] The fixture 50 may include: a fixture base 51 having a generally rectangular plate shape; and a first guide member 54, a second guide member 56, and a third guide member 60, each protruding upward from the fixture base 51. The fixture base 51 may extend in the second direction like the first film layer 302 and the second film layer 312.

[0175] The first film layer 302 may be placed on the fixture base 51. When the first film layer 302 is placed on the fixture base 51 in the first film layer setting step S510, the first guide member 54 blocks two opposite ends of the first film layer 302 in the second direction to prevent the first film layer 302 from sliding relative to the fixture 50 in the second direction. For example, the opposite ends of the first film layer 302 in the second direction may be the right end and the left end of the first film layer 302.

[0176] There may be four first guide members 54. Among these four first guide members 54, a pair of first guide members 54 blocks the left end of the first film layer 302. Another pair of first guide members 54 blocks the right end of the first film layer 302. The pair of first guide members 54 blocking the left end of the first film layer 302 may be spaced apart from each other in the third direction, and the pair of first guide members 54 blocking the right end of the first film layer 302 may be spaced apart from each other in the third direction.

[0177] The first film layer 302 may be formed with guide member placement grooves 309 recessed at both its right end and left end so that the first guide member 54 can be placed thereon. When the first guide member 54 is placed on the guide member placement groove 309, it is possible to prevent the first film layer 302 from inadvertently moving on the fixture base 51 in the third direction.

[0178] The second guide member 56 blocks the end portions of each of the plurality of plate members 330, 340, 350 in the second direction in the plate member setting step S520 to prevent the plurality of plate members 330, 340, 350 from sliding relative to the first film layer 302.

[0179] There may be a pair of second guide members 56. One of the pair of second guide members 56 may block the left end of each of the respective base portions 331, 341, 351 of the plurality of plate members 330, 340, 350. The other of the pair of second guide members 56 may block the right end of each of the respective base portions 331, 341, 351 of the plurality of plate members 330, 340, 350. Each of the pair of second guide members 56 may extend in the third direction.

[0180] The third guide member 60 blocks the end portions of each of the first plate member 330 and the third plate member 350 in the first direction and the second direction in the plate member setting step S520 to prevent the first plate member 330 and the third plate member 350 from sliding relative to the first film layer 302. There may be four third guide members 60. Each of the third guide members 60 may have an "L" shape in a plan view.

[0181] One of the four third guide members 60 may block the upper left corner of the base portion 331 of the first plate member 330. Another of the four third guide members 60 may block the upper right corner of the base portion 331 of the first plate member 330. The third of the four third guide members 60 may block the lower left corner of the base portion 351 of the third plate member 350. The remaining one of the four third guide members 60 may block the lower right corner of the base portion 351 of the third plate member 350.

[0182] Referring to Figure 21 、 Figure 22 and Figure 24 , in the plate member setting step S520, the plurality of plate members 330, 340, 350 are placed on the first film layer 302. The plurality of plate members 330, 340, 350 may be placed on the first film layer 302 such that their base portions 331, 341, 351 contact the first film layer 302 and their bent portions 334, 344, 354 protrude in the first direction.

[0183] For example, in the case where the first plate member 330 is placed on the first film layer 302, the upper left corner of the base portion 331 of the first plate member 330 may contact one of the third guide members 60 provided at the upper left end of the jig base 51, and the upper right corner of the base portion 331 of the first plate member 330 may contact the other third guide member 60 provided at the upper right end of the jig base 51.

[0184] In addition, the lower left corner of the base portion 331 of the first plate member 330 can contact both the second guide member 56 provided at the left side of the jig base 51 and the upper first guide member 54 among the pair of first guide members 54 provided at the left side of the jig base 51.

[0185] In addition, the lower right corner of the base portion 331 of the first plate member 330 can contact both the second guide member 56 provided at the right side of the jig base 51 and the upper first guide member 54 among the pair of first guide members 54 provided at the right side of the jig base 51. As a result, it is possible to prevent the first plate member 330 from inadvertently moving on the first film layer 302 in both the second direction and the third direction.

[0186] When the third plate member 350 is placed on the first film layer 302, the lower left corner of the base portion 351 of the third plate member 350 can contact the third guide member 60 provided at the lower left end of the jig base 51, and the lower right corner of the base portion 351 of the third plate member 350 can contact the other third guide member 60 provided at the lower right end of the jig base 51.

[0187] In addition, the upper left corner of the base portion 351 of the third plate member 350 can contact both the second guide member 56 provided at the left side of the jig base 51 and the lower first guide member 54 among the pair of first guide members 54 provided at the left side of the jig base 51.

[0188] In addition, the upper right corner of the base portion 351 of the third plate member 350 can contact both the second guide member 56 provided at the right side of the jig base 51 and the lower first guide member 54 among the pair of first guide members 54 provided at the right side of the jig base 51. As a result, it is possible to prevent the third plate member 350 from inadvertently moving on the first film layer 302 in both the second direction and the third direction.

[0189] When the second plate member 340 is placed on the first film layer 302, the upper left corner of the base portion 341 of the second plate member 340 can contact both the second guide member 56 provided at the left side of the jig base 51 and the upper first guide member 54 among the pair of first guide members 54 provided at the left side of the jig base 51, and the upper right corner of the base portion 341 can contact both the second guide member 56 provided at the right side of the jig base 51 and the upper first guide member 54 among the pair of first guide members 54 provided at the right side of the jig base 51.

[0190] In addition, the lower left corner of the base portion 341 of the second plate member 340 can contact both the second guide member 56 provided at the left side of the jig base 51 and the lower first guide member 54 among the pair of first guide members 54 provided at the left side of the jig base 51, and the lower right corner of the base portion 341 can contact both the second guide member 56 provided at the right side of the jig base 51 and the lower first guide member 54 among the pair of first guide members 54 provided at the right side of the jig base 51.

[0191] As a result, it is possible to prevent the second plate member 340 from inadvertently moving on the first film layer 302 in both the second direction and the third direction. The first plate member 330 can be spaced apart from the second plate member 340 by a distance corresponding to the width of the first guide member 54 in the third direction, and the second plate member 340 can be spaced apart from the third plate member 350 by a distance corresponding to the width of the first guide member 54 in the third direction.

[0192] Referring to Figure 21 、 Figure 22 and Figure 25 In the second film layer setting step S530, the second film layer 312 for the end plate assembly 301 is placed on the jig 50 to cover the first film layer 302 and the plurality of plate members 330, 340, 350.

[0193] When the second film layer 312 is placed on the jig base 51 of the jig 50 in the second film layer setting step S530, the first guide member 54 blocks the right end and the left end of the second film layer 312 in the second direction to prevent the second film layer 312 from sliding relative to the jig 50 in the second direction.

[0194] The second film layer 312 may be formed with guide member placement grooves 319 recessed at its right end and left end so that the first guide member 54 can be placed thereon. When the first guide member 54 is placed on the guide member placement grooves 319, it is possible to prevent the second film layer 312 from inadvertently moving along the third direction on the base portion 51.

[0195] In the second film layer setting step S530, the flange portion 356 of the third plate member 350 can pass through the flange portion penetration slit 321.

[0196] Referring to Figure 21 、 Figure 22 and Figure 26 In the film layer bonding step S540, the first film layer 302 and the second film layer 312 are bonded to each other to bond the plurality of plate members 330, 340, 350 to the first film layer 302 and the second film layer 312.

[0197] The film layer bonding step S540 may include a hot pressing step of heating the first film layer 302 and the second film layer 312 to melt and bond them together while pressing against each other.

[0198] The hot pressing step can be performed with the first film layer 302, the plurality of plate members 330, 340, 350, and the second film layer 312 placed on the jig base 51 of the jig 50 as shown in Figure 26 , or can be performed after removing the first film layer 302, the plurality of plate members 330, 340, 350, and the second film layer 312 from the jig 50.

[0199] Referring to Figure 8 and Figure 12 , the end plate assembly bonding step S500 can include firmly bonding a pair of end plate assemblies 301 to the opposite longitudinal ends of each of a pair of bus bar assemblies 200. Here, both ends 255 of the support plate 250 can be firmly bonded to the bent portions 334, 344, 354 of the plurality of plate members 330, 340, 350 using fasteners (such as bolts and nuts).

[0200] According to an embodiment of the present invention, the battery module includes a bus bar assembly, and the bus bar assembly includes a bus bar, a support film supporting the bus bar, and a support plate supporting the support film. Therefore, the use of a bus bar holder formed of metal for supporting the bus bar can be excluded, thereby reducing the associated costs, improving the component productivity, and enabling the battery module to be miniaturized and lightweight.

[0201] In addition, by using a flexible support film for supporting the bus bar, the tolerance for bonding the bus bar to the cell terminal between the bus bar and the cell terminal can be increased. As a result, welding failures between the bus bar and the cell terminal can be reduced, and the yield of high-quality battery module products can be improved.

[0202] However, the aspects and features of the present invention are not limited to the above aspects and features, and other aspects and features not mentioned will be clearly understood by those skilled in the art from the detailed description.

[0203] Although the present invention has been described with reference to some embodiments and drawings showing aspects of the present invention, the present invention is not limited thereto. Those skilled in the art within the field of the present invention can make various modifications and variations within the scope of the technical spirit of the present invention, the claims, and their equivalents.

Claims

1. A battery module, comprising: a plurality of battery cells arranged in a first direction and each including a cell housing and a cell terminal protruding from the cell housing; as well as A busbar assembly includes a busbar, a support film and a support plate, wherein the busbar electrically connects respective cell terminals of at least one pair of battery cells among the plurality of battery cells, the support film is bonded to the busbar to support the busbar, and the support plate is bonded to the support film to support the support film.

2. The battery module according to claim 1, wherein: The supporting film includes a first film layer for the bus bar assembly and a second film layer for the bus bar assembly, the second film layer being disposed over the first film layer and positioned farther from the plurality of battery cells than the first film layer.

3. The battery module according to claim 2, wherein: The bus bar and the support plate are disposed between the first film layer and the second film layer.

4. The battery module according to claim 3, wherein: The first film layer is bonded to the second film layer by heat compression; and The bus bar and the support plate are bonded to the support film through bonding between the first film layer and the second film layer.

5. The battery module according to claim 3, wherein: The support plate is formed with a bus bar window so that the support plate does not cover the bus bar.

6. The battery module according to claim 5, wherein: The first film layer is formed with a cell terminal contact window opening for enabling contact between the bus bar and the cell terminal.

7. The battery module according to claim 6, wherein: The second film layer is formed with a welding window having an opening for transferring energy for welding the bus bar to the cell terminal across the second film layer to the bus bar.

8. The battery module according to claim 1, wherein: The bus bar is formed with a bus bar guide pin hole into which a bus bar guide pin is fitted to guide a position of the bus bar relative to the support plate and the support film.

9. The battery module according to claim 1, wherein: Each of the plurality of battery cells includes a pair of cell terminals that protrude from the cell case in directions opposite to each other and intersecting a direction in which the plurality of battery cells are arranged.

10. The battery module according to claim 9, wherein: The bus bar assembly includes a pair of bus bar assemblies that cover the cell terminals and are spaced apart from each other with the plurality of battery cells arranged therebetween.

11. The battery module according to claim 1, wherein: The bus bar comprises: a first joining portion joined to a cell terminal of one of the plurality of battery cells; a second joining portion joined to a cell terminal of another battery cell among the plurality of battery cells; and The intermediate portion electrically connects the first joint portion to the second joint portion and deforms before the first joint portion and the second joint portion when an external force is applied to the bus bar.

12. The battery module according to claim 1, further comprising: an end plate assembly covering the outermost battery cells among the plurality of battery cells, Wherein, the end plate assembly comprises: a plurality of plates spaced apart from each other; a first membrane layer for the end plate assembly, the first membrane layer supporting the plurality of plates; and A second membrane layer for the end plate assembly is disposed on the first membrane layer and bonded to the first membrane layer with the plurality of plates disposed therebetween.

13. A method for manufacturing a battery module, the method comprising the following steps: manufacturing a bus bar assembly including a bus bar, a support film bonded to the bus bar to support the bus bar, and a support plate bonded to the support film to support the support film; arranging a plurality of battery cells each including a cell case and a cell terminal protruding from the cell case so that the cell terminal faces the bus bar; as well as The bus bar is joined to the cell terminal.

14. The method for manufacturing a battery module according to claim 13, wherein: The supporting film comprises a first film layer for the bus bar assembly and a second film layer for the bus bar assembly, the second film layer being arranged on the first film layer; and The bus bar and the support plate are disposed between the first film layer and the second film layer.

15. The method for manufacturing a battery module according to claim 14, wherein: The steps of manufacturing the busbar assembly include: a first film layer setting step, in which the first film layer is placed on a fixture for the busbar assembly; a bus bar setting step, in which the bus bar is placed on the first film layer; a support plate setting step, in which the support plate is placed on the first film layer; a second film layer disposing step, in which the second film layer is placed on the fixture to cover the first film layer, the bus bar and the support plate; and a film layer bonding step in which the first film layer is bonded to the second film layer to form a support film to which the bus bar and the support plate are bonded.

16. The method for manufacturing a battery module according to claim 15, wherein: The first film layer extends in a direction along which the plurality of battery cells are arranged; and The fixture comprises: a first guide pin, blocking a longitudinal end of the first film layer in the first film layer setting step to prevent the first film layer from sliding relative to the clamp in the longitudinal direction of the first film layer; as well as The second guide pin blocks a lateral end of the first film layer in the first film layer setting step to prevent the first film layer from sliding relative to the clamp in a lateral direction of the first film layer.

17. The method for manufacturing a battery module according to claim 16, wherein: The support plate extends in a direction along which the plurality of battery cells are arranged; and The fixture also includes: a third guide pin spaced apart from the first film layer and blocking a longitudinal end of the support plate to prevent the support plate from sliding relative to the fixture in the longitudinal direction of the support plate during the support plate setting step; as well as A fourth guide pin is spaced apart from the first film layer and blocks a lateral end of the support plate to prevent the support plate from sliding relative to the jig in a lateral direction of the support plate during the support plate setting step.

18. The method for manufacturing a battery module according to claim 15, wherein: The bus bar is formed with a bus bar guide pin hole; and The jig includes a bus bar guide pin fitted into the bus bar guide pin hole and passing through both the first film layer and the second film layer to lock the bus bar in position relative to the jig in the bus bar setting step.

19. The method for manufacturing a battery module according to claim 13, further comprising the following steps: manufacturing an end plate assembly, the end plate assembly comprising a plurality of plates spaced apart from each other, a first membrane layer for the end plate assembly, and a second membrane layer for the end plate assembly, the first membrane layer supporting the plurality of plates, the second membrane layer being disposed on the first membrane layer and bonded to the first membrane layer with the plurality of plates disposed between the first membrane layer and the second membrane layer; as well as The end plate assembly is coupled to the bus bar assembly.

20. The method for manufacturing a battery module according to claim 19, wherein: The steps of manufacturing the end plate assembly include: a first film layer setting step, in which the first film layer is placed on a fixture for the end plate assembly; a plate arrangement step, in which the plurality of plates are placed on the first film layer; a second film layer setting step, in which the second film layer is placed on the fixture to cover the first film layer and the plurality of plates; and A film layer bonding step, in which the first film layer is bonded to the second film layer to combine the plurality of panels to the first film layer and the second film layer.

Images