Intermediate bus bar unit, battery pack case including same, battery pack including same, and method of manufacturing same

Abstract

Disclosed are an intermediate bus bar unit, a battery pack case including the intermediate bus bar unit, a battery pack including the battery pack case, and a method of manufacturing the battery pack, the intermediate bus bar unit including: a conductive member electrically connected to a module terminal provided at a battery module; a first partition wall unit having a seating groove configured to allow the conductive member to be seated therein; and a second partition wall unit disposed on an upper portion of the first partition wall unit, in which the conductive member is configured such that both ends of the conductive member are exposed to different sides.

Description

Technical Field

[0001] This application claims the benefit of priority to Korean Patent Application No. 10-2024-0033075, filed on March 8, 2024, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to an inter-busbar unit, a battery housing including the inter-busbar unit, a battery pack including the battery housing, and a method for manufacturing the battery pack. More specifically, it relates to an inter-busbar unit that can be connected to a battery housing, a battery housing including the inter-busbar unit, a battery pack including the battery housing, and a method for manufacturing the battery pack. Background Technology

[0003] With the technological advancements and increasing demands of mobile devices, rechargeable batteries have been adopted as an energy source for various mobile devices. Rechargeable batteries have also attracted attention as an energy source for electric vehicles and hybrid electric vehicles, which are being proposed as alternatives to existing gasoline and diesel vehicles that use fossil fuels.

[0004] Based on the shape of the battery casing, secondary batteries are classified into cylindrical batteries, prismatic batteries, and pouch batteries. Cylindrical batteries have electrode assemblies installed in a cylindrical metal can, prismatic batteries have electrode assemblies installed in a prismatic metal can, and pouch batteries have electrode assemblies installed in a pouch-shaped casing made of aluminum laminate.

[0005] Currently widely used rechargeable batteries include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, and nickel-zinc batteries. The operating voltage of a single rechargeable battery cell (i.e., a single battery cell) is approximately 2.0V to 5.0V. Therefore, when an output voltage higher than the above operating voltage is required, multiple battery cells can be connected in series to form a cell module assembly. Furthermore, depending on the required output voltage or charge / discharge capacity, cell module assemblies can be connected in series or parallel to form a battery module, and battery packs are typically manufactured using at least one battery module by adding additional components.

[0006] However, lithium-ion batteries pose a risk of explosion due to overheating, making ensuring their safety a major challenge. Overheating can occur for various reasons, one of which is overcurrent flowing within the lithium-ion battery. Overcurrent causes the internal temperature of the battery to rise rapidly due to heat generation, and this rapid temperature rise can lead to thermal runaway, which may result in an explosion.

[0007] Figure 1 This is a schematic diagram of a battery pack using traditional busbars. (Example) Figure 1As shown, the battery pack can be configured such that a battery module M comprising multiple battery cells 1 is connected via a central busbar 4 to the external terminal 3 of another adjacent battery module M.

[0008] In this case, the following problem exists: the remaining portion of the intermediate busbar 4, except for the area of ​​the intermediate busbar that contacts the external terminal 3, is exposed to the discharge generated during thermal runaway, which increases the possibility of internal short circuits.

[0009] (Existing technical literature)

[0010] Patent Document 1: Korean Patent Publication No. 10-2015-0028073 Summary of the Invention

[0011] Technical issues

[0012] The present invention was made in view of the above problems, and the object of the present invention is to provide an intermediate busbar unit, a battery pack housing including the intermediate busbar unit, a battery pack including the battery pack housing, and a method of manufacturing the battery pack. The intermediate busbar unit is configured such that, except for the area of ​​the intermediate busbar unit that contacts the external terminals of the battery module, the remaining area of ​​the intermediate busbar unit is not exposed to discharge, thereby reducing the possibility of internal short circuits.

[0013] Technical solution

[0014] As a technical means to achieve the above-mentioned objectives, the intermediate busbar unit according to an embodiment of the present invention includes: a conductive member 110 electrically connected to a module terminal 310 disposed at a battery module 300; a first partition wall unit 120 having a mounting groove 121 configured to allow the conductive member 110 to be disposed therein; and a second partition wall unit 130 disposed on the upper part of the first partition wall unit 120, wherein the conductive member 110 is configured such that its two ends are exposed on different sides.

[0015] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the conductive member 110 may extend along the extension direction of the first partition wall unit 120, and the mounting groove 121 may be formed in the upper surface of the first partition wall unit 120 to extend along the extension direction.

[0016] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the first partition wall unit 120 may be provided with a first opening 122, which is formed such that one end of the conductive member 110 is exposed from the first side surface 120a facing the battery module 300 located on one side, and the second partition wall unit 130 may be provided with a third opening 131, which is formed at a position corresponding to the first opening 122, such that one end of the conductive member 110 is exposed from the third side surface 130a facing the battery module 300 located on one side.

[0017] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the first partition wall unit 120 may be provided with a second opening 123, which is formed such that the other end of the conductive member 110 is exposed from the second side surface 120b facing the battery module 300 located on the other side, and the second partition wall unit 130 may be provided with a fourth opening 132, which is formed at a position corresponding to the second opening 123, such that the other end of the conductive member 110 is exposed from the fourth side surface 130b facing the battery module 300 located on the other side.

[0018] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the first opening 122 and the second opening 123 may be formed at a position in the first partition wall unit 120 that does not overlap with each other in the thickness direction, and the third opening 131 and the fourth opening 132 may be formed at a position in the second partition wall unit 130 that does not overlap with each other in the thickness direction.

[0019] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the first partition wall unit 120 may have a protrusion 124 that protrudes upward on its upper surface, and the protrusion 124 may be provided at both ends of the first partition wall unit 120.

[0020] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the second partition wall unit 130 may have a recess 133 in its lower surface, the recess 133 being partially recessed upward at a position corresponding to the protrusion 124, and the recess 133 may be connected to the protrusion 124.

[0021] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the conductive member 110 may be made of a conductive material including a metallic material.

[0022] Furthermore, in the intermediate busbar unit according to an embodiment of the present invention, the insulating material 111 may be coated on the remaining area of ​​the outer surface of the conductive member 110, excluding the area in contact with the module terminal 310.

[0023] Additionally, according to an embodiment of the present invention, a battery pack housing including an intermediate busbar unit includes: an outer frame 210; a grid-shaped partition wall 220 disposed inside the outer frame 210, the partition wall being configured to form a plurality of receiving recesses 230, each receiving recess 230 being configured to receive a battery module 300; and an intermediate busbar unit 100 disposed on the upper part of the partition wall 220.

[0024] Furthermore, in the battery pack housing according to an embodiment of the present invention, the partition wall 220 may include: a first partition wall 221 disposed in a first direction parallel to the axial direction of the module terminal 310 of the battery module 300; and a second partition wall 222 disposed in a second direction perpendicular to the first direction.

[0025] Furthermore, in the battery pack housing according to an embodiment of the present invention, a connecting protrusion 221a that protrudes upward in part may be formed on the upper surface of the first partition wall 221.

[0026] Furthermore, in the battery pack housing according to an embodiment of the present invention, a connecting recess 125 may be formed in the lower surface of the first partition wall unit 120. The connecting recess 125 is partially recessed upward at a position corresponding to the connecting protrusion 221a, and the connecting recess 125 may be connected to the connecting protrusion 221a.

[0027] In addition, according to an embodiment of the present invention, a battery pack including a battery pack housing includes a battery pack housing 200 and a plurality of battery modules 300. The battery pack housing 200 includes an intermediate busbar unit 100, an outer frame 210 and a partition wall 220, and each of the battery modules 300 has a module terminal 310.

[0028] Furthermore, in a battery pack including a battery pack housing according to an embodiment of the present invention, a plurality of battery modules 300 may be configured such that the position of the module terminal 310 of each battery module 300 does not overlap with the position of the module terminal 310 of the battery module 300 closest to that battery module in the second direction.

[0029] In addition, a method for manufacturing a battery pack including a battery pack housing according to an embodiment of the present invention includes the following steps: (S1) accommodating a plurality of battery modules 300 in a plurality of accommodating recesses 230; (S2) connecting the connecting recess 125 of the intermediate busbar unit 100 and the connecting protrusion 221a of the first partition wall 221 to each other, such that the intermediate busbar unit 100 and the first partition wall 221 are connected to each other; and (S3) making the module terminal 310 electrically contact the conductive member 110.

[0030] Furthermore, in the method for manufacturing a battery pack including a battery pack housing according to an embodiment of the present invention, in step (S1), a plurality of battery modules 300 may be configured such that the position of the module terminal 310 of each battery module 300 does not overlap with the position of the module terminal 310 of the battery module 300 closest to that battery module in the second direction.

[0031] Furthermore, the method for manufacturing a battery pack including a battery pack housing according to an embodiment of the present invention may further include the following step: after step (S3), adding an insulating material to the upper surface of the conductive member 110.

[0032] Beneficial effects

[0033] As can be clearly seen from the above description, in the intermediate busbar unit, the battery pack housing including the intermediate busbar unit, the battery pack including the battery pack housing, and the method of manufacturing the battery pack according to the present invention, the intermediate busbar unit is embedded in the partition wall, and except for the portion of the intermediate busbar unit that is electrically connected to the module terminals provided at the battery module, the intermediate busbar unit is wrapped with insulating members, thereby preventing internal short circuits even if the discharge generated during the thermal runaway of the battery cell is dispersed and accumulated on the intermediate busbar unit. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of a battery pack with traditional busbars.

[0035] Figure 2 This is a perspective view of an intermediate busbar unit according to an embodiment of the present invention.

[0036] Figure 3 This is an exploded perspective view of an intermediate busbar unit according to an embodiment of the present invention.

[0037] Figure 4 This is a conceptual diagram showing the assembly of an intermediate busbar unit according to an embodiment of the present invention.

[0038] Figure 5 This is a conceptual diagram showing an intermediate busbar unit disposed on a partition wall according to an embodiment of the present invention.

[0039] Figure 6 This is a view showing a battery pack housing according to an embodiment of the present invention.

[0040] Figure 7 This is a view showing a battery pack including a battery pack housing according to an embodiment of the present invention.

[0041] Figure 8 yes Figure 7 An enlarged view of A is shown. Detailed Implementation

[0042] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, enabling those skilled in the art to readily implement these preferred embodiments. However, in describing the operational principles of the preferred embodiments of the present invention, detailed descriptions of known functions and configurations incorporated herein will be omitted where such descriptions might obscure the subject matter of the invention.

[0043] Furthermore, the same reference numerals will be used throughout the accompanying drawings to refer to components that perform similar functions or operations. Throughout the specification, when a component is referred to as being connected to another component, this means not only that one component can be directly connected to the other component, but also that one component can be indirectly connected to the other component via another component. Additionally, unless otherwise stated, including a predetermined element does not imply the exclusion of other elements, but rather indicates that such elements may be further included.

[0044] The intermediate busbar unit according to the present invention will be described below.

[0045] Figure 2 This is a perspective view of an intermediate busbar unit according to an embodiment of the present invention. Figure 3 This is an exploded perspective view of an intermediate busbar unit according to an embodiment of the present invention. Figure 4 This is a conceptual diagram illustrating the assembly of an intermediate busbar unit according to an embodiment of the present invention, and Figure 5 This is a conceptual diagram showing an intermediate busbar unit according to an embodiment of the present invention mounted on a partition wall. Additionally, Figure 6 This is a view showing a battery pack housing according to an embodiment of the present invention. Figure 7 This is a view showing a battery pack including a battery pack housing according to an embodiment of the present invention. Figure 8 yes Figure 7 An enlarged view of A shown in the image.

[0046] Reference Figures 2 to 8 The intermediate busbar unit 100 includes a conductive member 110, a first partition wall unit 120, and a second partition wall unit 130.

[0047] First, the conductive member 110 can be configured to be electrically connected to the module terminal 310 disposed at the battery module 300. For example, both ends of the conductive member 110 can contact the module terminal 310, thereby allowing the conductive member 110 to be electrically connected to the module terminal 310.

[0048] The conductive member 110 may be made of a conductive material including metallic materials. For example, the conductive member 110 may be made of a metal plate. More specifically, the conductive member 110 may be made of copper, aluminum, nickel, gold, silver, or a combination thereof.

[0049] The conductive member 110 can extend along the extension direction of the first partition wall unit 120. Figure 2 (in the direction from 11 o'clock to 5 o'clock). For example, the conductive member 110 may extend along the extension direction of the first partition wall unit 120, and the extension length of the conductive member 110 may be smaller than the extension length of the first partition wall unit 120. Here, the extension length of the conductive member 110 may be in the extension direction (from 11 o'clock to 5 o'clock). Figure 2 The length extending from 11 o'clock to 5 o'clock in the middle.

[0050] Furthermore, the end of the conductive member 110 can be bent in different directions. For example, one end of the conductive member 110 can be bent in different directions. Figure 2 It bends in the 2 o'clock direction, and the other end of the conductive component can be bent in the 2 o'clock direction. Figure 2 It bends in the 8 o'clock direction.

[0051] When adjacent battery modules 300 are arranged in different directions, the conductive member 110 can electrically connect the module terminals 310 of the adjacent battery modules 300.

[0052] Additionally, insulating material 111 can be applied to the remaining area of ​​the outer surface of the conductive member 110, excluding the two ends, which are the areas that contact the module terminals 310.

[0053] The insulating material 111 can be an external insulating material that forms part of the intermediate busbar unit and can prevent current flow during subsequent battery pack manufacturing. For example, the insulating material 111 can be at least one of polybutylene terephthalate (PBT), plastic, inorganic oxide, or non-conductive metal.

[0054] A mounting groove 121 for mounting the conductive member 110 may be formed in the first partition wall unit 120, and the mounting groove 121 may be formed in the upper surface of the first partition wall unit 120 to extend in the extension direction.

[0055] The mounting groove 121 can be formed to correspond to the extension length of the conductive member 110. For example, the mounting groove 121 can be formed at a height corresponding to the thickness of the conductive member 110. In another example, the mounting groove 121 can be formed at a height corresponding to half (1 / 2) of the thickness of the conductive member 110. However, the height of the mounting groove 121 is not limited to this and can be formed to accommodate a portion of the conductive member 110.

[0056] If the height of the mounting groove 121 of the first partition wall unit 120 is smaller than the height of the conductive member 110, a receiving recess (not shown) may be formed in the second partition wall unit 130 to accommodate the remaining area of ​​the conductive member 110 after it is placed in the mounting groove 121.

[0057] The second partition wall unit 130 can be disposed on the first partition wall unit 120. That is, the conductive member 110 can be inserted between the first partition wall unit 120 and the second partition wall unit 130.

[0058] The first partition wall unit 120 may have a protrusion 124 on its upper surface, the protrusion 124 being partially upward ( Figure 3 The protrusion 124 (at the 12 o'clock position) protrudes. The protrusion 124 can be provided at both ends of the first partition wall unit 120.

[0059] In other words, the protrusion 124 can be provided at both ends of the first partition wall unit 120, excluding the area forming the mounting groove 121.

[0060] Additionally, the second partition wall unit 130 may be located on its lower surface ( Figure 3 A recessed portion 133 is provided in the 6 o'clock position of the first partition wall unit 120, and the recessed portion 133 is partially recessed upward at the position of the protrusion 124 of the first partition wall unit 120.

[0061] The recess 133 can be configured to connect to the protrusion 124. The protrusion 124 and the recess 133 can be configured to have corresponding shapes.

[0062] Here, the correspondence between the protrusion 124 and the recess 133 in shape can mean that the protrusion and the recess are configured to engage with each other, and the recess 133 is formed into a shape that is larger than the protrusion 124, so that the protrusion 124 can be inserted into the recess 133, and a predetermined gap is formed between the outer surface of the protrusion 124 and the inner surface of the recess 133.

[0063] In addition, a recessed portion that is partially recessed downwards may be provided on the upper surface of the first partition wall unit 120, and a protruding portion that is partially protruding downwards may be provided on the lower surface of the second partition wall unit 130.

[0064] Furthermore, each of the first partition wall unit 120 and the second partition wall unit 130 may be made of the same material as partition wall 220. A detailed description will be given later.

[0065] The first partition wall unit 120 may be provided with a first opening 122, which is formed such that one end of the conductive member 110 is exposed from a first side surface 120a facing the battery module 300 located on one side. For example, the first opening 122 may be formed by extending the mounting groove 121 to expose one end of the conductive member 110 from the first side surface 120a.

[0066] The second partition wall unit 130 may be provided with a third opening 131, which is formed at a position corresponding to the first opening 122, such that one end of the conductive member 110 is exposed from the third side surface 130a facing the battery module 300 located on one side. For example, the third opening 131 may be formed by the extension of a receiving recess (not shown) that exposes one end of the conductive member 110 from the third side surface 130a.

[0067] The first opening 122 and the third opening 131 can be formed at corresponding positions to form a single hole when they overlap, and one end of the conductive member 110 can be exposed through the hole.

[0068] The first side surface 120a of the first partition wall unit 120 and the third side surface 130a of the second partition wall unit 130 may be side surfaces in the same direction.

[0069] Additionally, the first partition wall unit 120 may be provided with a second opening 123, which is formed such that the other end of the conductive member 110 is exposed from the second side surface 120b facing the battery module 300 located on the other side. For example, the second opening 123 may be formed by extending the mounting groove 121 to expose the other end of the conductive member 120 from the second side surface 120b.

[0070] The second partition wall unit 130 may be provided with a fourth opening 132, which is formed at a position corresponding to the second opening 123, such that the other end of the conductive member 110 is exposed from the fourth side surface 130b facing the battery module 300 located on the other side. For example, the fourth opening 132 may be formed by the extension of a receiving recess (not shown) that exposes the other end of the conductive member 110 from the fourth side surface 130b.

[0071] The second opening 123 and the fourth opening 132 can be formed at corresponding positions to form a single hole when they overlap, and the other end of the conductive member 110 can be exposed through the hole.

[0072] The second side surface 120b of the first partition wall unit 120 and the fourth side surface 130b of the second partition wall unit 130 may be side surfaces in the same direction.

[0073] The first opening 122 and the second opening 123 can be formed at positions in the first partition wall unit 120 that do not overlap with each other in the thickness direction, and the third opening 131 and the fourth opening 132 can be formed at positions in the second partition wall unit 130 that do not overlap with each other in the thickness direction.

[0074] Therefore, the two ends of the conductive member 110 can be exposed on different sides.

[0075] In addition, the extended portion of the conductive member 110, except for the two ends exposed on different sides, can be accommodated in the placement groove 121 of the first partition wall unit 120 and the receiving recess (not shown) of the second partition wall unit 130, so that the area exposed to the discharge is minimized, thereby reducing the possibility of the conductive member 110 coming into contact with spark particles compared with the prior art.

[0076] The following will describe a battery pack housing and a battery pack including an intermediate busbar unit according to the present invention.

[0077] First, the battery pack housing 200 includes an outer frame 210, a partition wall 220, and an intermediate busbar unit 100. Additionally, the battery pack housing 200 may include an upper housing (not shown) and a lower housing (not shown).

[0078] First, the outer frame 210 can have empty spaces therein, and multiple battery modules 300 and partition walls 220 can be accommodated in the empty spaces. For example, the outer frame 210 can be configured as a box when connected to the upper housing (not shown) and the lower housing (not shown).

[0079] The partition wall 220 may include a first partition wall 221 and a second partition wall 222. The partition wall 220 may be disposed in the outer frame 210 and may be arranged in a grid pattern to form a plurality of receiving recesses 230 configured to receive the battery module 300.

[0080] The first partition wall 221 can be set in the axial direction ( Figure 7 In a first direction parallel to the 12 o'clock to 6 o'clock position, the module terminals 310 of the battery module 300 are disposed in this axial direction. Additionally, the second partition wall 222 may be disposed in a second direction perpendicular to the first direction.

[0081] For example, the second partition wall 222 may be disposed in the middle of the outer frame 210 in the first direction, and the first partition wall 221 may be disposed spaced apart from the outer frame 210 so as to correspond to the total width of the battery module 300.

[0082] The distance between the outer frame 210 and the second partition wall 222 corresponds to the total length of the battery module 300, and the distance between the outer frame 210 and the first partition wall 221 or between the first partition wall 221 and the first partition wall 221 can correspond to the total width of the battery module 300.

[0083] When the first partition wall 221 and the second partition wall 222 are configured as described above, the outer frame 210 and the partition wall 220 can form a plurality of receiving recesses 230 configured to accommodate the battery module 300. The size of each of the plurality of receiving recesses 230 can correspond to the size of the battery module 300.

[0084] In addition, the intermediate busbar unit 100 can be mounted on the partition wall 220.

[0085] More specifically, the intermediate busbar unit 100 may be mounted on the first partition wall 221 to electrically connect the module terminals 310 of the battery modules 300 that are adjacent to each other in a second direction and housed in a plurality of receiving recesses 230.

[0086] A connecting protrusion 221a that protrudes upward partially may be formed on the upper surface of the first partition wall 221. One or more connecting protrusions 221a may be provided to form on the upper surface of the first partition wall 221.

[0087] Additionally, a connecting recess 125 may be formed in the lower surface of the first partition wall unit 120 of the intermediate busbar unit 100 disposed on the upper surface of the first partition wall 221. The connecting recess 125 is partially recessed upward at a position corresponding to the connecting protrusion 221a.

[0088] The connecting recess 125 can be configured to connect to the connecting protrusion 221a. The connecting protrusion 221a and the connecting recess 125 can be configured to have corresponding shapes.

[0089] Here, the fact that the connecting protrusion 221a and the connecting recess 125 correspond to each other in shape means that the connecting protrusion and the connecting recess are configured to engage with each other. The connecting recess 125 is formed into a shape that is larger than the connecting protrusion 221a, so that the connecting protrusion 221a can be inserted into the connecting recess 125, and a predetermined gap is formed between the outer surface of the connecting protrusion 221a and the inner surface of the connecting recess 125.

[0090] In addition, a partially recessed connecting recess may be formed on the upper surface of the first partition wall 221, and a partially protruding connecting protrusion may be formed on the lower surface of the first partition wall unit 120.

[0091] The height of the first partition wall 221 is preferably large enough that when the intermediate busbar unit 100 is placed on the upper surface of the first partition wall, the two ends of the conductive member 110 can be placed on the upper surface of the module terminal 310.

[0092] In addition, the intermediate busbar unit 100 can be installed on the second partition wall 222 as needed.

[0093] Furthermore, the battery pack according to an embodiment of the present invention includes a battery pack housing 200 and a battery module 300.

[0094] As described above, the battery pack housing 200 includes an intermediate busbar unit 100, an outer frame 210, and a partition wall 220. The battery pack housing 200 including the intermediate busbar unit 100 is the same as described above, so a more detailed description of it will be omitted.

[0095] The battery module 300 may include a cell assembly (not shown), a module housing (not shown), and module terminals 310.

[0096] First, the cell assembly (not shown) may include multiple battery cells. A battery cell may be a pouch-shaped secondary battery comprising an electrode assembly, electrode leads, and a battery casing.

[0097] The electrode assembly can be: a wound-core type electrode assembly configured to have a structure in which an elongated negative electrode and an elongated positive electrode are wound with a separator inserted therebetween; a stacked electrode assembly comprising unit cells, each unit cell being configured to have a structure in which a rectangular positive electrode and a rectangular negative electrode are stacked with a separator inserted therebetween; a stacked folded electrode assembly configured to have a structure in which the unit cells are wound with a long separator; or a laminated stacked electrode assembly configured to have a structure in which the unit cells are stacked with a separator inserted therebetween and then attached to each other; however, the invention is not limited thereto.

[0098] The positive electrode includes a positive current collector and positive active material coated on each of the upper and lower surfaces of the positive current collector. The positive active material may be mixed with conductive agents and binders, and fillers may be added further as needed.

[0099] The negative electrode includes a negative current collector and a negative active material coated on each of the upper and lower surfaces of the negative current collector. The negative active material may be further mixed with a conductive agent and a binder, and the negative current collector may be coated with this mixture.

[0100] The diaphragm prevents short circuits between the negative and positive electrodes and allows only lithium ion migration. The diaphragm is preferably made of any one of polyethylene, polypropylene, a bilayer of polyethylene / polypropylene, a trilayer of polyethylene / polypropylene / polypropylene, a trilayer of polypropylene / polypropylene / polypropylene, and organic fiber filter paper; however, the invention is not limited thereto.

[0101] The battery housing that houses the electrode assembly is made of a laminate comprising an outer cover layer, a metal layer, and an inner cover layer, and has a housing portion formed therein.

[0102] The inner cover layer is in direct contact with the electrode assembly, therefore it needs to exhibit high insulation and high electrolytic resistance. Furthermore, the inner cover layer needs to exhibit high sealing performance to hermetically isolate the battery casing from the outside; that is, the thermally bonded seal between the inner layers needs to exhibit excellent thermal bond strength.

[0103] The inner cover can be made of materials selected from polyolefin-based resins (e.g., polypropylene, polyethylene, polyethylene acrylate, or polybutene), polyurethane resins, and polyimide resins, which exhibit excellent chemical resistance and high sealing performance; however, the invention is not limited thereto, and polypropylene is most preferably used, which exhibits excellent mechanical properties (e.g., tensile strength, rigidity, surface hardness, and impact resistance) and excellent chemical resistance.

[0104] The metal layer that abuts the inner cover layer corresponds to the barrier layer, which is configured to prevent moisture or various gases from penetrating into the battery from the outside. Lightweight and easily formable aluminum film is a preferred material for the metal layer.

[0105] An outer cover layer is disposed on the other surface of the metal layer, and the outer cover layer can be made of a heat-resistant polymer exhibiting excellent tensile strength, resistance to moisture penetration, and resistance to air permeability, so that the outer cover layer exhibits high heat resistance and chemical resistance while protecting the electrode assembly. As an example, the outer cover layer can be made of nylon or polyethylene terephthalate; however, the invention is not limited thereto.

[0106] Additionally, the module housing (not shown) can accommodate the battery cell assembly (not shown) within its defined internal space. The battery module 300 according to the invention is not particularly limited in shape or configuration, and various battery modules 300 can be provided.

[0107] The battery module 300 includes module terminals 310 and can be configured in multiple ways. Multiple battery modules 300 can be respectively accommodated in multiple receiving recesses 230 of the battery pack housing 200.

[0108] At this time, the multiple battery modules 300 can be configured such that the position of the module terminal 310 of each battery module 300 does not overlap with the position of the module terminal 310 of the battery module 300 closest to it in the second direction.

[0109] Reference Figure 7 and Figure 8 The module terminal 310a of the first battery module 300a can be configured to face the 6 o'clock direction, and the module terminal 310b of the second battery module 300b can be configured to face the 12 o'clock direction. In this case, one end of the intermediate busbar unit 100 can be electrically connected to the module terminal 310a of the first battery module 300a, and the other end of the intermediate busbar unit 100 can be electrically connected to the module terminal 310b of the second battery module 300b.

[0110] Next, refer to Figures 2 to 8 A method for manufacturing a battery pack according to an embodiment of the present invention is described.

[0111] The method for manufacturing a battery pack according to the present invention includes the following steps: (S1) accommodating a plurality of battery modules 300 in a plurality of accommodating recesses 230; (S2) connecting the connecting recess 125 of the intermediate busbar unit 100 and the connecting protrusion 221a of the first partition wall 221 to each other, such that the intermediate busbar unit 100 and the first partition wall 221 are connected to each other; and (S3) making the module terminal 310 electrically contact the conductive member 110.

[0112] In step (S1), the battery module 300 can be configured such that the position of the module terminal 310 of each battery module 300 does not overlap with the position of the module terminal 310 of the battery module 300 closest to it in the second direction.

[0113] For example, in step (S3), when the module terminal 310 is in electrical contact with the conductive member 110, the conductive member 110 may be disposed on the upper surface of the module terminal 310 to make electrical contact with it, or the conductive member may be connected to the module terminal by means of bolts.

[0114] Additionally, the method for manufacturing a battery pack according to the present invention may include adding an insulating material to the upper surface of the conductive member 110 after step (S3). Here, the insulating material may be heat-resistant silicone resin or insulating tape.

[0115] Although the specific details of the invention have been described in detail, those skilled in the art will understand that the detailed description only discloses preferred embodiments of the invention and therefore does not limit the scope of the invention. Therefore, those skilled in the art will understand that various changes and modifications can be made without departing from the scope and concept of the invention, and it will be apparent that such changes and modifications fall within the scope of the appended claims.

[0116] (Explanation of reference numerals in the attached diagram)

[0117] 100: Intermediate busbar unit

[0118] 110: Conductive component; 111: Insulating material

[0119] 120: First partition wall unit

[0120] 120a: First side surface; 120b: Second side surface

[0121] 121: Installation groove

[0122] 122: First opening 123: Second opening

[0123] 124: Protrusion 125: Connecting Recess

[0124] 130: Second partition wall unit

[0125] 130a: First side surface; 130b: Second side surface

[0126] 131: Third opening 132: Fourth opening

[0127] 133: Depression

[0128] 200: Battery pack casing

[0129] 210: External Framework

[0130] 220: Partition wall

[0131] 221: First partition wall; 221a: Connecting protrusion

[0132] 222: Second partition wall

[0133] 300: Battery module; 310: Module terminal

Claims

1. An intermediate busbar unit, the intermediate busbar unit comprising: A conductive component, wherein the conductive component is electrically connected to a module terminal disposed at the battery module; A first partition wall unit has a mounting groove configured to allow the conductive member to be placed in the mounting groove; as well as The second partition wall unit is disposed on the upper part of the first partition wall unit, wherein, The conductive member is configured such that its two ends are exposed on different sides.

2. The intermediate busbar unit according to claim 1, wherein, The conductive member extends along the extension direction of the first partition wall unit, and The placement groove is formed in the upper surface of the first partition wall unit and extends along the extension direction.

3. The intermediate busbar unit according to claim 2, wherein, The first partition wall unit is provided with a first opening, the first opening being formed such that one end of the conductive member is exposed from a first side surface facing the battery module located on one side, and The second partition wall unit is provided with a third opening, which is formed at a position corresponding to the first opening, such that one end of the conductive member is exposed from a third side surface facing the battery module located on one side.

4. The intermediate busbar unit according to claim 3, wherein, The first partition wall unit is provided with a second opening, the second opening being formed such that the other end of the conductive member is exposed from a second side surface facing the battery module located on the other side, and The second partition wall unit is provided with a fourth opening, which is formed at a position corresponding to the second opening, such that the other end of the conductive member is exposed from the fourth side surface facing the battery module located on the other side.

5. The intermediate busbar unit according to claim 4, wherein, The first opening and the second opening are formed at positions in the first partition wall unit that do not overlap with each other in the thickness direction, and The third opening and the fourth opening are formed at positions in the second partition wall unit that do not overlap with each other in the thickness direction.

6. The intermediate busbar unit according to claim 1, wherein, The first partition wall unit has a partially upward-protruding protrusion on its upper surface, and The protrusions are located at both ends of the first partition wall unit.

7. The intermediate busbar unit according to claim 6, wherein, The second partition wall unit has a recess in its lower surface, the recess being partially recessed upwards at a position corresponding to the protrusion, and The recess is configured to connect to the protrusion.

8. The intermediate busbar unit according to claim 1, wherein, The conductive component is made of a conductive material including metallic materials.

9. The intermediate busbar unit according to claim 8, wherein, Insulating material is applied to the outer surface of the conductive component, excluding the area in contact with the module terminals.

10. A battery pack housing, the battery pack housing comprising an intermediate busbar unit according to any one of claims 1 to 9, the battery pack housing comprising: External framework; A grid-shaped partition wall is disposed inside the outer frame and is configured to form a plurality of receiving recesses, each receiving recess being configured to receive the battery module; as well as The intermediate busbar unit is mounted on the upper part of the partition wall.

11. The battery pack housing according to claim 10, wherein, The partition wall includes: A first partition wall is disposed in a first direction parallel to the axial direction of the module terminals on which the battery module is disposed; and The second partition wall is disposed in a second direction perpendicular to the first direction.

12. The battery pack housing according to claim 11, wherein, A connecting protrusion that protrudes upward is formed on the upper surface of the first partition wall.

13. The battery pack housing according to claim 12, wherein, A connecting recess is formed in the lower surface of the first partition wall unit, and the connecting recess is partially recessed upward at a position corresponding to the connecting protrusion. The connecting recess is configured to connect to the connecting protrusion.

14. A battery pack, the battery pack comprising a battery pack housing according to any one of claims 10 to 13, the battery pack comprising: The battery pack housing includes the intermediate busbar unit, the outer frame, and the partition wall; as well as Multiple battery modules, each battery module having the module terminals.

15. The battery pack according to claim 14, wherein, The plurality of battery modules are configured such that the position of the module terminal of a battery module does not overlap with the position of the module terminal of the battery module closest to that battery module in the second direction.

16. A method for manufacturing a battery pack according to any one of claims 14 and 15, the method comprising the following steps: (S1) The plurality of battery modules are housed in the plurality of receiving recesses; (S2) Connect the connecting recess of the intermediate busbar unit to the connecting protrusion of the first partition wall, so that the intermediate busbar unit and the first partition wall are connected to each other; and (S3) Make the module terminals electrically contact the conductive component.

17. The method according to claim 16, wherein, In step (S1), the battery module is configured such that the position of the module terminal of the battery module does not overlap with the position of the module terminal of the battery module closest to the battery module in the second direction.

18. The method of claim 16, further comprising the step of: After step (S3), insulating material is added to the upper surface of the conductive member (110).

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