Secondary battery and method for manufacturing same

Abstract

The invention discloses a secondary battery and a manufacturing method thereof. The secondary battery includes: a case having an opening; an electrode assembly inserted into the case through the opening, the electrode assembly including a curved electrode tab; a terminal electrically connected to the bent electrode tab of the electrode assembly, the terminal being exposed to the outside of the case; a cover sealing the opening of the housing; and an electrode plate insulating member that electrically insulates the electrode assembly from the terminal.

Description

[0001] This application claims priority to and the benefit of Korean Patent Application No. 10-2024-0095249, filed on July 18, 2024, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. TECHNICAL FIELD

[0002] Aspects of embodiments of the present disclosure relate to a secondary battery including an electrode assembly inserted laterally and a method of manufacturing the same. BACKGROUND

[0003] Unlike primary batteries that are not designed to be (re)charged, secondary batteries are batteries designed to be (re)charged and discharged. Low-capacity secondary batteries are used for portable small electronic devices such as smartphones, feature phones, laptop computers, digital cameras, and camcorders, and high-capacity secondary batteries are widely used as power sources to drive electric motors in hybrid vehicles, electric vehicles, etc., and energy storage batteries. A secondary battery generally includes an electrode assembly formed of a positive electrode and a negative electrode, a case for accommodating the electrode assembly, and an electrode terminal connected to the electrode assembly.

[0004] Secondary batteries generally include (or can be classified into) cylindrical batteries, pouch-type batteries, and prismatic batteries. In the case of pouch-type secondary batteries among these types of secondary batteries, an electrode assembly (e.g., a jelly-roll electrode assembly) is assembled by being inserted laterally into a pouch. In the case of prismatic batteries, an electrode assembly is assembled by being inserted vertically into a case or by being inserted laterally into an opening in a side surface of a case.

[0005] In the case of prismatic batteries in which an electrode assembly is assembled by being inserted laterally into an opening in a side surface of a case, if the size of the electrode assembly is increased to increase the capacity of the battery (e.g., energy storage capacity), it is difficult to insert and assemble the electrode assembly into the case due to a decrease in empty space in the case.

[0006] The above information disclosed in this Background section is for enhancement of understanding of the background of the present disclosure, and therefore, it can contain information not constituting the related (or prior) art. SUMMARY

[0007] Embodiments of the present disclosure provide a secondary battery having a configuration that allows an electrode assembly having a maximum size to be easily assembled within a limited space by improving a method of manufacturing a secondary battery in which the electrode assembly is inserted laterally into an opening in a side surface of a case and assembled there.

[0008] According to an embodiment of the present disclosure, a secondary battery includes: a housing having an opening; an electrode assembly inserted into the housing through the opening; and includes: an electrode plate having bent electrode tabs; terminals exposed outside the housing and electrically connected to the bent electrode tabs of the electrode assembly; a cover sealing the opening of the housing; and an electrode plate insulating member electrically insulating the electrode plate of the electrode assembly from the terminals.

[0009] According to another aspect of this disclosure, a method of manufacturing a secondary battery includes: manufacturing a housing having an opening and a cover for sealing the opening; manufacturing an electrode assembly including electrode tabs; manufacturing terminals to be connected to the housing and connecting the terminals to the housing; connecting the electrode tabs of the electrode assembly to the terminals connected to the housing; bending the electrode tabs of the electrode assembly; inserting the electrode assembly with the bent electrode tabs into the housing through the opening of the housing; applying an electrode plate insulating member to electrically insulate the electrode plates of the electrode assembly from the terminals; and sealing the opening of the housing with the cover.

[0010] According to another embodiment of this disclosure, a secondary battery includes: a housing having an opening; an electrode assembly inserted into the housing and including an electrode plate and a bent electrode tab connected to the electrode plate; a first terminal exposed outside the housing and electrically connected to the bent electrode tab of the electrode assembly; a second terminal not exposed outside the housing; and an electrode plate insulating member including a first insulating portion electrically insulating the second terminal from the electrode plate of the electrode assembly and a second insulating portion electrically insulating the first terminal from the electrode plate of the electrode assembly.

[0011] The aspects and features of this disclosure are not limited to those described above, and those skilled in the art will clearly understand other aspects and features not specifically mentioned herein through the following description of this disclosure. Attached Figure Description

[0012] The following accompanying drawings illustrate embodiments of the present disclosure, and together with the following detailed description, further describe aspects and features of the present disclosure. Therefore, the present disclosure should not be construed as limited to the drawings, wherein:

[0013] Figure 1 This is a schematic diagram of the electrode assembly of a secondary battery;

[0014] Figure 2A This is a top perspective view of the appearance of a secondary battery according to some embodiments of the present disclosure;

[0015] Figure 2B yes Figure 2A An exploded perspective view of the secondary battery shown;

[0016] Figure 3 It is along Figure 2A A cross-sectional view taken along the centerline I-I';

[0017] Figure 4 is a cross-sectional view taken along Figure 2A the center line II-II';

[0018] Figure 5 is a perspective view illustrating an inside and a terminal portion of a case of a secondary battery according to some embodiments of the present disclosure;

[0019] Figures 6A-6C is a diagram illustrating steps of an assembly process of a case-electrode assembly according to some embodiments of the present disclosure;

[0020] Figures 7A-7C is a diagram illustrating an electrode plate insulation member;

[0021] Figures 8A-8D is a diagram illustrating steps of an assembly process of a case-electrode assembly according to other embodiments of the present disclosure;

[0022] Figures 9A-9D is a diagram illustrating steps of an assembly process of a case-electrode assembly according to other embodiments of the present disclosure;

[0023] Figure 10 is a diagram illustrating a secondary battery module in which a secondary battery according to some embodiments of the present disclosure is disposed;

[0024] Figure 11 is a perspective view of a secondary battery module including Figure 10 a secondary battery module illustrated in FIG. 1; and

[0025] Figure 12 is a conceptual diagram illustrating a vehicle including Figure 11 a secondary battery module illustrated in FIG. 1. DETAILED DESCRIPTION

[0026] Some embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. The terms or words used in the present specification and claims should not be interpreted as being restricted according to their common or dictionary meanings, and should be interpreted as having a concept matching the technical idea of the present disclosure based on the principle that an inventor is able to appropriately define the concept of terms to best describe his or her own example embodiments.

[0027] The embodiments described in the present specification and the configurations illustrated in the accompanying drawings are only some of the embodiments of the present disclosure, and do not represent all aspects, features, and embodiments of the present disclosure. Therefore, it should be understood that, at the time of filing the present application, various equivalents and modifications capable of replacing or modifying one or more embodiments or features described herein can exist.

[0028] It will be understood that if a component or layer is described as being "on" another component or layer, "connected to," or "attached to" another component or layer, then it can be directly on, directly connected to, or attached to that other component or layer, or one or more intermediate components or layers may exist. When a component or layer is described as being "directly on" another component or layer, "directly connected to," or "directly attached to" another component or layer, then no intermediate components or layers exist. For example, when a first component is described as being "attached" or "connected" to a second component, then the first component can be directly attached to or connected to the second component, or the first component can be indirectly attached to or connected to the second component via one or more intermediate components.

[0029] In the figures, for clarity of illustration, the dimensions of various elements, layers, etc., may be large. The same reference numerals indicate the same elements. As used herein, the term "and / or" includes any and all combinations of one or more associated listed items. Furthermore, the use of "may" in describing embodiments of this disclosure refers to "one or more embodiments of this disclosure." When expressions such as "at least one of..." and "any one of..." follow a list of elements, they modify the entire list of elements, not individual elements in the list. When a list of elements A, B, and C is specified using terms such as "at least one of A, B, and C," "at least one selected from the group of A, B, and C," or "at least one selected from A, B, and C," the term may 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 term "use" and variations thereof may be considered synonymous with the term "utilize" and variations thereof. As used herein, the terms “substantially,” “approximately,” and similar terms are used as approximate terms rather than as terms of degree, and are intended to take into account the inherent variations in measurements or calculations that would be apparent to a person skilled in the art.

[0030] It will be understood that although the terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, area, layer, or portion discussed below may be referred to as the second element, component, area, layer, or portion.

[0031] For purposes of the description hereinafter, spatial or directional terms, such as, for example, "below," "lower," "bottom," "above," and "upper" are used with reference to the exemplary illustrated orientation of the device as shown in the figures. It will be understood that the spatial and directional terms are used for purposes of the descriptions hereinafter and that the device can be oriented in other orientations than the one depicted in the figures. For example, if the device in the figures were turned over, then the elements or features described as being "below" or "under" other elements or features would then be oriented "above" or "over" the other elements or features. Thus, the term "below" can encompass both an orientation of above and below. The device can be oriented in other ways (rotated 90°, or in other orientations), and the spatially relative descriptors used herein are to be interpreted accordingly.

[0032] The terminology used herein is for the purpose of describing embodiments of the present disclosure and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "includes" and / or "including," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0033] Furthermore, any numerical ranges herein are intended to include all sub-ranges of the same whole number recited, as implicitly disclosed as being within the range. For example, a range from 1.0 to 10.0 should be read to include a range from a limit of 1.0 to a limit of 10.0, that is, all sub-ranges beginning with either 1.0 or

[0034] Referring to two compared elements, features, etc., as "the same" can mean that they are "substantially the same." Thus, "substantially the same" can include having a deviation that is considered low in the art, for example, about 5% or less. Also, when a certain parameter is said to be uniform in a given region, this can mean that it is uniform in terms of average value.

[0035] Throughout the specification, unless otherwise indicated, each element can be singular or plural.

[0036] Arranging an arbitrary element "on (or under)" or "above (or below)" another element can mean that the arbitrary element can be in contact with the upper surface (or lower surface) of the element, and still another element can be inserted between the element and the arbitrary element positioned on (or under) the element.

[0037] Further, it will be understood that if a component is referred to as being "linked", "coupled", or "connected" to another component, the component can be directly linked, coupled, or connected to the other component, or a further component can be "interposed" between the components.

[0038] Throughout the specification, unless otherwise stated, when "A and / or B" is stated, it means A, B, or A and B. That is, "and / or" includes any or all combinations of the listed items. Unless otherwise indicated, when "C to D" is stated, it means C or above and D or below.

[0039] The terms used herein are used for the purpose of describing embodiments of the present disclosure, and are not intended to limit the present disclosure.

[0040] Figure 1 An electrode assembly of a secondary battery is illustrated.

[0041] Referring to Figure 1 The electrode assembly 10 can be formed by winding or stacking a stack of the first electrode plate 11, the separator 12, and the second electrode plate 13, each of which is formed as a thin plate or film. When the electrode assembly 10 is a wound stack, the winding axis can be parallel to the longitudinal direction of the case. In other embodiments, the electrode assembly 10 can be a stacked type rather than a wound type, and the shape of the electrode assembly 10 is not limited in the present disclosure. Further, the electrode assembly 10 can be a Z-stacked electrode assembly in which a positive electrode plate and a negative electrode plate are inserted to both sides (e.g., opposite sides) of a separator, and then bent (or folded) into a Z-stacked stack. Further, one or more electrode assemblies can be stacked (e.g., arranged) such that the long sides of the electrode assemblies are adjacent to each other and are accommodated in the case, and in the present disclosure, the number of electrode assemblies in the case is not limited. The first electrode plate 11 of the electrode assembly 10 can be used as a negative electrode, and the second electrode plate 13 can be used as a positive electrode. Of course, the reverse is also possible.

[0042] The first electrode plate 11 can be formed by applying (e.g., coating or depositing) a first electrode active material such as graphite or carbon to a first electrode substrate formed of a metal foil such as copper, a copper alloy, nickel, or a nickel alloy. The first electrode plate 11 can include a first electrode tab 14 (e.g., a first uncoated portion) as a region to which the first electrode active material is not applied. The first electrode tab 14 can be connected to an external first terminal. In some embodiments, when the first electrode plate 11 is manufactured, the first electrode tab 14 can be formed by being pre-cut to protrude to one side of the electrode assembly 10 (or protrude from one side of the electrode assembly 10), or the first electrode tab 14 can protrude more than (e.g., farther or beyond) the separator 12 to the one side of the electrode assembly 10 without being separately cut.

[0043] The second electrode plate 13 can be formed by applying (e.g., coating or depositing) a second electrode active material such as a transition metal oxide to a second electrode substrate formed of a metal foil such as aluminum or an aluminum alloy. The second electrode plate 13 can include a second electrode tab 15 (e.g., a second uncoated portion) as a region to which the second electrode active material is not applied. The second electrode tab 15 can be connected to an external second terminal. In some embodiments, when the second electrode plate 13 is manufactured, the second electrode tab 15 can be formed by being pre-cut to protrude to the other side (e.g., the opposite side) of the electrode assembly 10, or the second electrode tab 15 can protrude more than (e.g., farther or beyond) the separator 12 to the other side of the electrode assembly 10 without being separately cut.

[0044] The separator 12 prevents short-circuiting between the first electrode plate 11 and the second electrode plate 13 while allowing lithium ions to move therebetween. The separator 12 can be made of, for example, a polyethylene film, a polypropylene film, a polyethylene polypropylene film, or the like.

[0045] In some embodiments, the electrode assembly 10 can be accommodated in a case together with an electrolyte solution. In a pouch-type secondary battery, the electrode assembly 10 can be accommodated in a pouch made of a flexible material. In a cylindrical or prismatic secondary battery, the electrode assembly 10 can be accommodated in a cylindrical or prismatic metal case.

[0046] Hereinafter, suitable materials that can be used for a secondary battery according to embodiments of the present disclosure will be described.

[0047] As a positive electrode active material, a compound capable of reversibly intercalating / deintercalating lithium (e.g., a lithiated intercalation compound) can be used. For example, at least one of a composite oxide of lithium and a metal selected from cobalt, manganese, nickel, and combinations thereof can be used.

[0048] The complex oxide can be a lithium transition metal complex oxide, examples of which can include a lithium nickel-based oxide, a lithium cobalt-based oxide, a lithium manganese-based oxide, a lithium iron phosphate-based compound, a cobalt-free nickel manganese-based oxide, or a combination thereof.

[0049] For example, a compound represented by any one of the following molecular formulas can be used: Li a A 1-b X b O 2-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Mn 2-b X b O 4-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Ni 1-b-c Co b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni 1-b- c Mn b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni b Co c L 1 d G e O2(0.90≤a≤1.8, 0≤b≤0.9, 0≤c≤0.5, 0≤d≤0.5, 0≤e≤0.1); Li a NiG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a CoG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-b G b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn2G b O4(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-g Gg PO4(0.90≤a≤1.8, 0≤g≤0.5); Li (3-f) Fe2(PO4)3(0≤f≤2); and Li a FePO4(0.90≤a≤1.8).

[0050] In the above formula: A is Ni, Co, Mn, or a combination thereof; X is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, a rare earth element, or a combination thereof; D is O, F, S, P, or a combination thereof; G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, or a combination thereof; and L 1 is Mn, Al, or a combination thereof.

[0051] A positive electrode for a lithium secondary battery can include a positive electrode substrate and a positive electrode active material layer formed on the positive electrode substrate. The positive electrode active material layer can include a positive electrode active material, and can further include a binder and / or a conductive material.

[0052] The content of the positive electrode active material is in the range of about 90 wt% to about 99 wt% based on 100 wt% of the positive electrode active material layer, and the content of the binder and the conductive material is in the range of about 0.5 wt% to about 5 wt% based on 100 wt% of the positive electrode active material layer, respectively.

[0053] The positive electrode substrate can be an aluminum (Al) foil, but is not limited thereto.

[0054] The negative electrode active material can include a material capable of reversibly intercalating / deintercalating lithium ions, lithium metal, a lithium metal alloy, a material capable of doping and undoping lithium, or a transition metal oxide.

[0055] The material capable of reversibly intercalating / deintercalating lithium ions can be a carbon-based negative electrode active material, which can include, for example, crystalline carbon, amorphous carbon, or a combination thereof. Examples of the crystalline carbon can include graphite, such as natural graphite or artificial graphite, and examples of the amorphous carbon can include soft carbon, hard carbon, mesophase pitch carbide, sintered coke, or the like.

[0056] The Si-based negative electrode active material or the Sn-based negative electrode active material can be used as the material capable of doping and undoping lithium. The Si-based negative electrode active material can be silicon, a silicon-carbon composite, SiO x (0 < x ≤ 2), a Si-based alloy, or a combination thereof.

[0057] The silicon-carbon composite can be a composite of silicon and amorphous carbon. According to an embodiment, the silicon-carbon composite can be in the form of silicon particles and amorphous carbon coated on the surface of the silicon particles.

[0058] The silicon-carbon composite can further include crystalline carbon. For example, the silicon-carbon composite can include a core including crystalline carbon and silicon particles, and an amorphous carbon coating layer on a surface of the core.

[0059] The negative electrode for a lithium secondary battery can include a negative electrode substrate and a negative electrode active material layer disposed on the negative electrode substrate. The negative electrode active material layer can include a negative electrode active material, and can further include a binder and / or a conductive material.

[0060] For example, the negative electrode active material layer can include about 90 wt% to about 99 wt% of a negative electrode active material, about 0.5 wt% to about 5 wt% of a binder, and about 0 wt% to about 5 wt% of a conductive material.

[0061] A non-aqueous binder, an aqueous binder, a dry binder, or a combination thereof can be used as the binder. When an aqueous binder is used as the negative electrode binder, a cellulose-based compound capable of imparting viscosity can be further included.

[0062] As the negative electrode substrate, one selected from a copper foil, a nickel foil, a stainless steel foil, a titanium foil, a nickel foam, a copper foam, a polymer substrate coated with a conductive metal, and a combination thereof can be used.

[0063] The electrolyte for a lithium secondary battery can include a non-aqueous organic solvent and a lithium salt.

[0064] The non-aqueous organic solvent serves as a medium through which ions participating in an electrochemical reaction of the battery can move.

[0065] The non-aqueous organic solvent can be a carbonate-based solvent, an ester-based solvent, an ether-based solvent, a ketone-based solvent, an alcohol-based solvent, an aprotic solvent, and can be used alone or in combination of two or more.

[0066] In addition, when a carbonate-based solvent is used, a mixture of a cyclic carbonate and a chain carbonate can be used.

[0067] According to the type of the lithium secondary battery, a separator can be present between a first electrode plate (for example, a negative electrode) and a second electrode plate (for example, a positive electrode). As the separator, polyethylene, polypropylene, polyvinylidene fluoride, or a multi-layer film including two or more layers thereof can be used.

[0068] The separator can include a porous substrate and a coating layer including an organic material, an inorganic material, or a combination thereof on one or both surfaces of the porous substrate.

[0069] The organic material can include a polyvinylidene fluoride-based polymer or a (meth)acrylate-based polymer.

[0070] The inorganic material can include inorganic particles selected from Al2O3, SiO2, TiO2, SnO2, CeO2, MgO, NiO, CaO, GaO, ZnO, ZrO2, Y2O3, SrTiO3, BaTiO3, Mg(OH)2, boehmite, and combinations thereof, but is not limited thereto.

[0071] The organic material and the inorganic material can be mixed in one coating layer, or can be in a form in which a coating layer including (or comprising) the organic material and a coating layer including (or comprising) the inorganic material are stacked on each other.

[0072] Figure 2A is a top perspective view of an appearance of a secondary battery according to some embodiments of the disclosure.

[0073] The case 22 can provide (or can form) a space in which the electrode assembly 10 is accommodated, for example, as shown in Figure 1 , and can form the overall appearance of the secondary battery. The case 22 can be formed of an electrically conductive metal such as aluminum, an aluminum alloy, nickel-plated steel, or a SUS (stainless steel) material.

[0074] The first terminal 24 and the second terminal 26 can be exposed to the outside of the case 22, and are mounted to be electrically connected to the first electrode tab 14 and the second electrode tab 15 of the electrode assembly 10, respectively, which are inserted into the inside of the case 22.

[0075] An electrolyte inlet 28 can also be formed in the case 22, and a gas exhaust port (not shown) configured to open (e.g., break) in response to excess gas generated inside the battery to discharge gas (e.g., degassing) can also be formed.

[0076] Figure 2B is an exploded perspective view of a secondary battery shown in Figure 2A .

[0077] The secondary battery according to the present embodiment can have a structure in which a laterally wide surface of the case 22 is open and the electrode assembly 10 is inserted laterally into the opening and the cover 29 covers (e.g., seals) the opening. The first electrode tab 14 and the second electrode tab 15 of the electrode assembly 10 can be connected to the first terminal 24 and the second terminal 26 of the case 22 (which are exposed to the outside of the case 22) by welding in the inside of the case 22.

[0078] Figure 3 and Figure 4 are diagrams for describing a more detailed configuration of the secondary battery shown in Figure 2A and Figure 2B . Figure 3 is a cross-sectional view taken along the line I-I' in Figure 2A ,Figure 4 is a cross-sectional view taken along the line II-II' in Figure 2A .

[0079] First, referring to Figure 3 , the first terminal 24 can be connected or bonded to the case 22, and the second terminal 26 can be electrically insulated from the case 22 via the insulator 30 and can extend to the inside of the case 22. Accordingly, the second terminal 26 can have an inner terminal portion 27 that is inside the case 22. The insulator 30 can have an inner insulating portion 31 that is inside the case 22 to provide electrical insulation between the second terminal 26 and the case 22.

[0080] The first electrode tab 14 of the electrode assembly 10 that is inserted laterally into the inside of the case 22 can be welded to a welding portion of the inner surface of the case 22 and connected to the first terminal 24 through the case 22, and the second electrode tab 15 of the electrode assembly 10 can be connected (e.g., welded) to the inner terminal portion 27 of the second terminal 26. Reference numeral 33 indicates a welding portion (referred to as a first welding portion 33) at which the first electrode tab 14 is welded to the inner surface of the case 22, and reference numeral 35 indicates a welding portion (referred to as a second welding portion 35) at which the second electrode tab 15 is welded to the inner terminal portion 27 of the second terminal 26. The first electrode tab 14 and the second electrode tab 15 can be bent in the manner shown in Figure 4 in connection with the second electrode tab 15. Figure 4 The welding of the second electrode tab 15 of the electrode assembly 10 to the inner terminal portion 27 of the second terminal 26 and its subsequent bending (e.g., Figure 4 shows a cross-sectional view cut in the axial direction of the second terminal 26, and thus the bending structure of the first electrode tab 14 is not shown.

[0081] Due to the above assembly structure, the electrode plate insulating member 32 can be included to provide electrical insulation between the inside of the first terminal 24 and the electrode plate edge surface of the electrode assembly 10 and between the inner terminal portion 27 of the second terminal 26 and the electrode plate edge surface of the electrode assembly 10. In addition, because the inner surface of the cover 29, which covers the side surface after assembly, can come into contact with the bent portions of the first electrode tab 14 and the second electrode tab 15, the electrode plate insulating member 32 can also electrically insulate the bent portions from the cover 29.

[0082] The electrode plate insulating member 32 will be described in detail below in connection with a description of a manufacturing method, and its shape is as shown in Figure 7A and Figure 7B .

[0083] Conventionally, the electrode assembly 10 is inserted into the case 22 laterally, an insulating member is applied, and the case, the terminal, and the electrode tabs are connected by welding. In this case, the electrode tabs are formed relatively long to secure ease of work. However, in order to increase the battery capacity, the size of the electrode assembly 10 inserted into the case 22 can be increased (particularly, the area of the electrode plate), and thus, the first electrode tab 14 and the second electrode tab 15 can be formed relatively short, and the space between the inner surface of the case 22 and the electrode assembly 10 can be narrow. In a structure providing such an increase in battery capacity, after the electrode assembly is inserted into the case 22, it is difficult to bend and weld the short first electrode tab 14 and the second electrode tab 15 in the narrow space available as in the conventional assembly method.

[0084] Accordingly, according to an embodiment of the present disclosure, an assembly method allows an increase in battery capacity by forming the first electrode tab 14 and the second electrode tab 15 as short as possible to expand the effective area of the electrode assembly 10, and improves a method of applying an insulating member. The concept of the method of assembling an electrode assembly according to an embodiment of the present disclosure includes performing welding of the electrode tabs first, and then inserting the electrode assembly into the case. For example, the operations of electrode assembly assembly in a secondary battery manufacturing process can be performed in the following order: electrode tab welding; electrode tab bending; electrode assembly insertion; and insulating member insertion.

[0085] Figure 5 The upper inner surface of the case 22 and the terminal portion are shown. Figure 5 is illustrated to provide an understanding of Figure 3 and Figure 4 a perspective view of the respective portions of the structure shown in

[0086] Referring to Figure 5 , a first welding portion 33 for welding the first electrode tab 14 to the inner surface of the case 22 can be provided on the upper inner surface of the case 22, and a second welding portion 35 for welding the second electrode tab 15 to the inner terminal portion 27 of the second terminal 26 can be provided on the inner terminal portion 27. The first welding portion 33 and the second welding portion 35 can be plated with a material for facilitating welding of the first electrode tab 14 and the second electrode tab 15, or can be surface-treated to improve contact performance. However, the present disclosure is not limited thereto.

[0087] Figures 2A-4 The description of

[0088] Hereinafter, a method for manufacturing a secondary battery according to an embodiment of the present disclosure will be described. The structure of the above-described secondary battery according to the present disclosure will become clear through the following description of the manufacturing method.

[0089] Figures 6A-6C The steps of assembling a housing-electrode assembly according to some embodiments of the present disclosure are shown. Figures 8A-8D The steps of assembling a housing-electrode assembly according to some other embodiments of the present disclosure are shown. Figures 9A-9D The steps of assembling a housing-electrode assembly according to some other embodiments of the present disclosure are shown.

[0090] Figures 6A-6C The embodiment shown illustrates an assembly method in which the second electrode tab 15 of the electrode assembly 10 is arranged close to the outer side of the electrode plate edge surface 19 of the electrode assembly 10 (e.g., the outer side is the side exposed to the outside after the electrode assembly 10 is laterally inserted into the housing 22). Figures 8A-8D The embodiment shown illustrates an assembly method in which the electrode terminals of an electrode assembly 10 are arranged at the middle portion of the electrode assembly 10 (e.g., the middle portion is the middle position of the electrode plate edge surface 19 of the electrode assembly 10). Figures 9A-9D The embodiment shown illustrates an assembly method in which the electrode terminals of the electrode assembly 10 are arranged close to the inner side of the electrode plate edge surface 19 of the electrode assembly 10 (e.g., the inner side is the side that contacts the inner surface of the housing 22 after the electrode assembly 10 is laterally inserted into the housing 22).

[0091] First, refer to Figures 6A-6C This description describes an embodiment in which the second electrode connector 15 is arranged on the outer side of the electrode plate edge surface 19 of the electrode assembly 10. In the following description, for ease of understanding and drawing, a cross-sectional view of the electrode assembly 10 taken in the axial direction of the second electrode connector 15 will be used. Furthermore, the second terminal 26 and the second electrode connector 15 will be simply referred to as "terminal 26" and "electrode connector 15," respectively.

[0092] like Figure 6A As shown, with the housing 22 placed (e.g., placed on a surface) and the electrode assembly 10 erected (e.g., oriented perpendicular to the housing 22), the electrode tab 15 can be soldered to the inner terminal portion 27 of the terminal 26. Furthermore, the electrode tab 15 can be bent when the electrode assembly 10 rotates in direction B1 toward the housing 22.

[0093] Figure 6B It shows that in such Figure 6AThe electrode assembly 10 is rotated in the direction B1 shown and placed in the housing 22, and then the electrode plate insulating member 32 is applied. The electrode plate insulating member 32 may cover the electrode terminals 14 and 15, the inner surface of the housing 22, and the inner terminal portion 27, and may provide electrical insulation between the electrode plate edge surface 19 of the electrode assembly 10 and adjacent members. The shape of the electrode plate insulating member 32 will be described below.

[0094] After that, as Figure 6C As shown, the cover 29 can cover and seal the opening in the housing 22. In this embodiment, as described above, the shape of the electrode plate insulating member 32 can be designed such that the curved portion 36 of the electrode terminal block 15 does not contact the inner surface of the cover 29.

[0095] Figure 7A An embodiment of the electrode plate insulating member 32 is shown. Figure 7B This is a diagram showing the application of the electrode plate insulating member 32 to the housing 22, and Figure 7C The configuration after applying the electrode plate insulating member 32 to the housing 22 is shown. The electrode plate insulating member 32 insulates the electrode plate edge surface 19 of the electrode assembly 10 from the inner terminal portion 27 of the second terminal 26. Insulation between the second terminal 26, the cover 29, and the electrode plate edge surface 19 of the electrode assembly 10 is important because the first terminal 24 is coupled or connected to the housing 22 and the cover 29 is coupled to the housing 22. Otherwise, the first terminal 24 and the second terminal 26 may short-circuit. Furthermore, because the bent portion of the electrode tab has a protruding structure, the bent portion should also be electrically insulated from the inner surface of the corresponding portion of the cover 29. In various embodiments, the electrode plate insulating member 32 may include a first insulating portion that electrically insulates the inner terminal portion 27 of the second terminal 26 from the electrode plate of the electrode assembly. However, in various embodiments, the electrode plate insulating member 32 may optionally include a second insulating portion 37 for electrically insulating the inner side of the first terminal 24 (e.g., the inner surface of the housing 22) from the electrode plate of the electrode assembly. The second insulating portion 37 ensures a secure fit of the electrode plate insulating member 32. exist Figure 7AIn the middle, the portion indicated by reference numeral 38 of the electrode plate insulation member 32 can be coupled to the inner terminal portion 27 of the second terminal 26 to fix the electrode plate insulation member 32 and precisely ensure the insulation range. Further, reference numerals 41 can be holes (e.g., openings) for smoothly injecting an electrolyte, and reference numerals 39 and 40 can indicate portions fitted into the electrode tabs 14 and 15 of the electrode assembly 10. Further, as described above, reference numeral 34 indicates a third insulation portion that can be provided to provide insulation of the curved portion of the electrode tab from the inner surface of the cover 29. Because the third insulation portion 34 insulates the second terminal 26 and the curved portion 36 of the electrode tab from the cover 29 (e.g., from the inner surface of the cover) when the first terminal 24 has the same polarity as the cover 29, the third insulation portion 34 can not extend over the entire length of the electrode plate insulation member 32.

[0096] The shape of the electrode plate insulation member 32 can be designed to apply to the internal structure of the case shown in Figure 3 and Figure 5 and can depend on various shapes of the secondary battery design during actual manufacturing.

[0097] Next, an embodiment in which the electrode tab 15 is arranged in the middle portion of the electrode plate edge surface 19 of the electrode assembly 10 will be described with reference to Figures 8A-8D

[0098] As shown in Figure 8A , in a state in which the case 22 is placed and the electrode assembly 10 is erected, the electrode tab 15 can be welded to the inner terminal portion 27 of the terminal 26. Further, the bending blade 46 can be placed against the electrode tab 15 to assist in the rotation of the electrode assembly 10 in the direction B2, and the electrode assembly 10 can be rotated in the direction B2 away from the case 22, i.e., toward the outside of the surface on which the terminal 26 of the case 22 is arranged (e.g., first rotation or first bending).

[0099] Figure 8B A step of second-rotating the electrode assembly 10 is shown, the electrode assembly 10 is first rotated and bent in the direction B2 shown in Figure 8A along the arrow, and then rotated and bent in the direction B3 toward the case 22. In this embodiment, the bending blade 46 can be used to smoothly bend the electrode tab 15.

[0100] Figure 8C ​the state where the electrode assembly 10 is rotated and placed in the housing 22 for the second time and the state where the electrode plate insulation member 32 is inserted into the second welding portion 35 of the electrode tab 15 of the electrode assembly 10. It can be seen that the electrode assembly 10 is inserted into the housing 22, the electrode tab 15 is bent, and the electrode tab 15 of the electrode assembly 10 and the electrode plate edge surface (19) thereof are insulated by the electrode plate insulation member 32. Figure 9A

[0101] Thereafter, as shown in Figure 8D , the cover 29 can cover and seal the opening in the housing 22.

[0102] The description of the electrode plate insulation member 32 is the same as that described with reference to Figure 7A , Figure 7B , and Figure 7C .

[0103] Finally, an embodiment in which the electrode tab 15 is disposed inside the electrode plate edge surface 19 of the electrode assembly 10 will be described with reference to Figures 9A-9D .

[0104] As shown in Figure 9A , in the state where the housing 22 is placed and the electrode assembly 10 is erected, the electrode tab 15 can be welded to the inner terminal portion 27 of the terminal 26. Further, in order to rotate the electrode assembly 10 in the direction B4, the bending blade 46 can be placed against an appropriate position of the electrode tab 15, and the electrode assembly 10 can be rotated in the direction B4 away from the housing 22 and bent, i.e., rotated toward the outside of the surface on which the terminal 26 of the housing 22 is disposed (e.g., first rotation or first bending).

[0105] Figure 9B A step of rotating the electrode assembly 10, which is first rotated and bent in the arrow B4 direction in Figure 9A , in the direction B5 toward the housing 22 for the second time is shown. In this step, the electrode tab 15 can be smoothly bent using the bending blade 46.

[0106] Figure 9C The state where the electrode assembly 10 is rotated and placed in the housing 22 for the second time and the state where the electrode plate insulation member 32 is inserted into the second welding portion 35 of the electrode tab 15 of the electrode assembly 10 are shown. It can be seen that the electrode assembly 10 is inserted into the housing 22, the electrode tab 15 is bent, and the electrode tab 15 of the electrode assembly 10 and the electrode plate edge surface (19) thereof are insulated by the electrode plate insulation member 32. Figure 9A

[0107] Thereafter, as shown in Figure 9D , the cover 29 can cover and seal the opening of the housing 22. ​​

[0108] The electrode plate insulating member 32 is described with reference to Figure 7A , Figure 7B and Figure 7C the same as the description of

[0109] Figure 10 is a perspective view of a secondary battery module in which secondary batteries are arranged according to an embodiment of the present disclosure. As the capacity of secondary batteries for driving electric vehicles and the like increases, a secondary battery module can be manufactured by arranging a plurality of secondary battery cells laterally and / or longitudinally and connecting them. A plurality of secondary batteries can be arranged in a space defined by a pair of opposing end plates 68a and 68b and a pair of opposing side plates 69a and 69b. The secondary batteries can be arranged in one arrangement direction and in a number to obtain a required voltage and current specification.

[0110] Figure 11 is a perspective view of a battery pack 70 according to an embodiment of the present disclosure. With reference to Figure 11 , the battery pack 70 can include an assembly to which individual cells are electrically connected and a pack case that houses the assembly. In the drawing, components including bus bars, a cooling unit, external terminals for electrically connecting the cells, and the like are not shown for ease of illustration.

[0111] The battery pack 70 can be installed on (or in) a vehicle. For example, the vehicle can be an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle. The vehicle can be a four-wheel drive vehicle or a two-wheel drive vehicle, but is not limited thereto. Figure 12 A vehicle V is shown, including a battery pack 70 as shown in Figure 11 on a lower body thereof. The vehicle V can be operated by receiving electric power from the battery pack 70 (e.g., can be driven by the battery pack 70).

[0112] According to an embodiment of the present disclosure, the electrode assembly is inserted laterally into an opening in a side surface of the case (e.g., into an opening of the case) and assembled thereto, so that the electrode assembly having the largest dimension can be easily assembled in a limited space. Therefore, even when the tabs of the electrode assembly are formed to be short and the area of the electrode assembly increases, tab welding, tab bending, insulating member installation, and insertion of the electrode assembly into the case can be easily performed, so that the capacity of the battery can be expanded without sacrificing production costs.

[0113] While the present disclosure has been described above with reference to embodiments thereof, it is not limited thereto. Various modifications and variations can be made to the present disclosure by those skilled in the art in the light of the teachings thereof as defined by the claims and their equivalents.

Claims

1. A secondary battery comprising: a case having an opening; an electrode assembly inserted into the case through the opening, the electrode assembly including an electrode plate having a curved electrode tab; a terminal electrically connected to the curved electrode tab of the electrode assembly, the terminal being exposed to an outside of the case; a cover sealing the opening of the case; and an electrode plate insulation member electrically insulating the electrode plate of the electrode assembly from the terminal. The terminal includes:

2. The secondary battery according to claim 1, wherein a first terminal bonded to the case; and a second terminal having an inner terminal portion electrically insulated from the case by an insulator and extending to an inside of the case. The curved electrode tab of the electrode assembly includes:

3. The secondary battery according to claim 2, wherein a first curved electrode tab welded to an inner surface of the case and connected to the first terminal through the case; and a second curved electrode tab connected to the inner terminal portion of the second terminal. The electrode plate insulation member includes a first insulation portion electrically insulating the inner terminal portion of the second terminal from the electrode plate of the electrode assembly.

4. The secondary battery according to claim 2, wherein The electrode plate insulation member includes a second insulation portion electrically insulating the first terminal from the electrode plate of the electrode assembly.

5. The secondary battery according to claim 2, wherein The electrode plate insulation member includes a third insulation portion electrically insulating an inner surface of the cover from a curved portion of the curved electrode tab.

6. The secondary battery according to claim 1, wherein The curved portion of the curved electrode tab faces the cover.

7. The secondary battery according to claim 1, wherein The curved electrode tab is connected to the terminal by welding, and 8. The secondary battery according to claim 1, wherein wherein the terminal includes a welding portion at which the electrode tab is welded to the terminal. 9.A method of manufacturing a secondary battery, the method comprising: manufacturing a case having an opening and a cover configured to seal the opening; manufacturing an electrode assembly including an electrode tab; manufacturing a terminal to be coupled to the case and coupling the terminal to the case; connecting the electrode tab of the electrode assembly to the terminal coupled to the case; curving the electrode tab of the electrode assembly; inserting the electrode assembly having the curved electrode tab into the case through the opening of the case; applying an electrode plate insulation member to electrically insulate the electrode plate of the electrode assembly from the terminal; and sealing the opening of the case with the cover. The coupling of the terminal to the case includes: bonding a first terminal to the case; and 10. The method of claim 9, wherein, electrically insulating a second terminal from the case and connecting the second terminal to the case. The connecting of the electrode tab of the electrode assembly to the terminal coupled to the case includes: welding a first electrode tab to an inner surface of the case and connecting the first electrode tab to the first terminal through the case; and 11. The method of claim 10, wherein, connecting a second electrode tab to the second terminal by welding. The electrode plate insulation member includes a first insulation portion to electrically insulate an inner terminal portion of the second terminal from the electrode plate of the electrode assembly. ​ 12. The method of claim 10, wherein, ​ 13. The method of claim 10, wherein, The electrode plate insulation member includes a second insulation portion to electrically insulate the first terminal from the electrode plate of the electrode assembly.

14. The method of claim 9, wherein, The electrode plate insulation member includes a third insulation portion to electrically insulate an inner surface of the cover from a curved portion of the curved electrode tab.

15. The method of claim 9, wherein, The bending the electrode tab of the electrode assembly includes bending a curved portion of the electrode tab to face the cover.

16. The method of claim 9, wherein, The bending the electrode tab of the electrode assembly includes rotating the electrode assembly having the electrode tab connected to the terminal away from the case.

17. The method of claim 9, wherein, The bending the electrode tab of the electrode assembly includes: first, rotating the electrode assembly having the electrode tab connected to the terminal away from the case, and second, rotating the rotated electrode assembly toward the case.

18. The method of claim 9, wherein, The bending the electrode tab of the electrode assembly includes rotating the electrode assembly by placing a bending blade against the electrode tab connected to the terminal.

19. A secondary battery comprising: a case having an opening; an electrode assembly inserted into the case, the electrode assembly including an electrode plate and a curved electrode tab connected to the electrode plate; a first terminal electrically connected to the curved electrode tab of the electrode assembly, the first terminal being combined to the case; a second terminal having an inner terminal portion inside the case; and an electrode plate insulation member electrically insulating the first terminal and the second terminal from the electrode plate of the electrode assembly, wherein the electrode plate insulation member includes: a first insulation portion electrically insulating the inner terminal portion of the second terminal from the electrode assembly; and a second insulation portion electrically insulating the first terminal from the electrode assembly.

20. The secondary battery of claim 19, further comprising a cover sealing the opening of the case, the electrode plate insulation member further including a third insulation portion electrically insulating an inner surface of the cover from a curved portion of the curved electrode tab. wherein, ​

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