Battery pack and method of manufacturing battery pack

Abstract

The present application provides a battery pack and a method of manufacturing the same, the battery pack including a battery case, a plurality of battery cell stacks housed inside the battery case and arranged to be spaced apart from each other in a first direction, and a bus bar disposed between the plurality of battery cell stacks, the bus bar extends in a second direction crossing the first direction between the plurality of battery cell stacks in the first direction. The battery case includes a substrate on which the plurality of battery cell stacks are disposed, a first spanning member extending in a second direction between the plurality of battery cell stacks, and a bus bar holding device fixing a position of a bus bar between the first spanning member and the substrate. The method of assembly includes mounting the bus bar, mounting the battery cell stack around the bus bar, attaching the spanning member, and connecting the cover. The design simplifies alignment of busbars, provides secure electrical connections, and has a compact structure suitable for use in high efficiency battery systems.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Korean Patent Application No. 10-2024-0137127, filed with the Korean Intellectual Property Office on October 8, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to battery packs and methods for manufacturing them. Background Technology

[0004] In recent years, with increasing environmental awareness and dwindling oil resources, the research and development of electric vehicles, as environmentally friendly vehicles, has received considerable attention. Electric vehicles include plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), and fuel cell electric vehicles (FCEVs).

[0005] Electric vehicles typically include a battery casing that supports the battery cells. Electric vehicles use battery cells as their power source, and recent efforts have focused on increasing the capacity of the battery cells housed within the battery casing.

[0006] To increase the capacity of battery cells, they can be arranged in a CTP (cell-to-pack) structure within the battery casing, rather than being grouped into modules. Simultaneously, a busbar for high voltage can be installed inside the battery casing. However, the presence of the busbar and the components supporting it necessitates cost reduction.

[0007] Furthermore, if a fire occurs because the battery cells are inside the battery casing, the fire can spread rapidly. Therefore, there is an increasing need for measures to prevent or mitigate thermal runaway near the busbar. Summary of the Invention

[0008] At least some embodiments of this application are intended to address the aforementioned problems existing in the prior art, while maintaining the advantages achieved by the prior art.

[0009] Some exemplary embodiments of this application provide a battery pack that reduces busbar costs while preventing thermal runaway caused by the busbar.

[0010] The technical problems to be solved by at least some embodiments of this application are not limited to those mentioned above, and any other technical problems not mentioned herein will be clearly understood by those skilled in the art through the following description.

[0011] According to some example embodiments of the present application, a battery pack includes a battery case, a plurality of battery cell stacks configured to be accommodated inside the battery case and arranged to be spaced apart from each other in a first direction, and a busbar extending between the plurality of battery cell stacks in a second direction crossing the first direction, and the battery case includes a base plate, a first spanning member extending between the plurality of battery cell stacks in the second direction, and a busbar holding device fixing a position of the busbar between the first spanning member and the base plate.

[0012] The busbar holding device can include a base wall fixed to the base plate and a pair of side walls extending from the base wall to one side of a third direction crossing the first direction and the second direction, and the busbar is accommodated between the pair of side walls.

[0013] The busbar holding device can further include a busbar support wall protruding from the base wall between the pair of side walls in the third direction and supporting the busbar.

[0014] A height of the busbar support wall in the third direction can be less than a height of the side wall in the third direction.

[0015] The battery pack can further include an intermediate busbar configured to electrically connect the battery cell stacks arranged side by side in the second direction, and the base wall can be configured to support the intermediate busbar.

[0016] The base wall can include a base region connected to the side wall and the busbar support wall, and a protruding region protruding from the base region toward the battery cell stacks and engaged to the intermediate busbar.

[0017] The intermediate busbar can extend in the second direction and include opposite end portions in the second direction, and the protruding region can be engaged to the opposite end portions of the intermediate busbar.

[0018] The battery pack can further include a second spanning member extending in the first direction and crossing the first spanning member between the opposite end portions of the intermediate busbar.

[0019] The battery pack can further include an engagement member engaging the opposite end portions of the intermediate busbar to the protruding region, and the busbar can include a region curved to become more distant from the opposite end portions of the intermediate busbar in the first direction when the busbar and the intermediate busbar are viewed in a state spaced apart in the third direction.

[0020] The intermediate bus bar can be disposed between the bus bar and the base wall.

[0021] When the bus bar and the intermediate bus bar are viewed in a state spaced apart in the second direction, a length of the intermediate bus bar in the first direction can be greater than a length in the third direction, and the bus bar can be spaced apart from the intermediate bus bar in the third direction such that a length of the bus bar in the third direction is greater than a length in the first direction.

[0022] The battery cell stack can include a battery cell extending in a first direction and arranged in a second direction, and a sensing assembly disposed at one side of the battery cell in the first direction and electrically connected to the intermediate bus bar.

[0023] The connection terminal can be disposed at an area opposite to the sensing assembly in the third direction.

[0024] The side wall can include a side connection area extending in the second direction, and a side support area arranged in the second direction with the side connection area interposed therebetween, a height of the side support area in the third direction being greater than a height of the side connection area in the third direction, and supporting the bus bar.

[0025] The side support area can include a portion having a thickness in the first direction greater than a thickness of the side connection area in the first direction.

[0026] The base plate can include a cooling passage inside the base plate.

[0027] According to some example embodiments of the present application, a method of manufacturing a battery pack includes: installing a bus bar to a battery case; installing a plurality of battery cell stacks to the battery case such that the plurality of battery cell stacks face each other with the bus bar interposed therebetween; installing a first spanning member between the plurality of battery cell stacks and a second spanning member in a direction crossing the first spanning member; and joining a battery pack cover to the battery case.

[0028] The installing of the bus bar to the battery case can include fixing a bus bar holding device for fixing the bus bar to the base plate, and seating the bus bar on the bus bar holding device.

[0029] The installing of the bus bar to the battery case can include fixing a bus bar holding device for fixing the bus bar to the base plate, and installing an intermediate bus bar for electrical connection of the battery cell stack to the battery case.

[0030] The installing of the plurality of battery cell stacks to the battery case can include electrically connecting the intermediate bus bar to the connection terminal of the battery cell stack. BRIEF DESCRIPTION OF DRAWINGS

[0031] The above and other objects, features and advantages of the present application will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0032] Figure 1 is an exploded perspective view of a battery pack according to some example embodiments of the present application;

[0033] Figure 2 is a perspective view of a battery case before installation of an electrical component module according to some example embodiments of the present application;

[0034] Figure 3 is a perspective view of a battery case installed with an electrical component module according to some example embodiments of the present application;

[0035] Figure 4 is Figure 3 is an enlarged view of a portion "A" shown in FIG. 1;

[0036] Figure 5 is Figure 3 is an enlarged view of a portion "B" shown in FIG. 1;

[0037] Figure 6 is Figure 3 is an enlarged view of a portion "C" shown in FIG. 1;

[0038] Figure 7 is a perspective view of a battery cell stack according to some example embodiments of the present application;

[0039] Figure 8 is an enlarged view showing an intermediate busbar, a connection terminal, and a busbar between battery cell stacks according to some example embodiments of the present application;

[0040] Figure 9 is a cross-sectional view of a busbar, an intermediate busbar, a connection terminal, and a substrate disposed between battery cell stacks according to some example embodiments of the present application;

[0041] Figure 10 is a flowchart showing a method of manufacturing a battery pack according to some example embodiments of the present application. DETAILED DESCRIPTION

[0042] Hereinafter, embodiments of the present application will be described in detail with reference to the accompanying drawings. In adding reference numerals to components of the drawings, it should be noted that the same components are designated by the same reference numerals even though they are illustrated in different drawings. Further, in describing embodiments of the present application, when it is determined that detailed description on related known configurations and functions will unnecessarily obscure the understanding of embodiments of the present application, a detailed description thereof will be omitted.

[0043] Also, in describing aspects of the present application, terms such as "first", "second", "A", "B", "(a)" and "(b)" can be used. These terms are used only for distinguishing one component from another, and the nature, order and sequence of the corresponding components are not limited by these terms. Unless otherwise defined, all terms including technical terms or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application pertains. Such terms, including technical terms or scientific terms, as defined in commonly used dictionaries are to be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0044] It should be understood that the terms "vehicle" or "vehicular" or other similar terms used herein generally include motor vehicles, such as passenger vehicles including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, watercraft including various boats and ships, aircraft, and the like, and include hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen powered vehicles, and other alternative fuel vehicles (e.g., fuels derived from non-petroleum sources). As referred to herein, a hybrid vehicle is a vehicle having two or more sources of power, such as a vehicle having both gasoline power and electric power.

[0045] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present application. 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. These terms are merely used to distinguish one component from another component, and these terms do not limit the nature, order and sequence of the components constituting the components. It will be further understood that the terms "comprises" and / or "comprising," 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. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Throughout this specification, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, but not to the exclusion of any other element. In addition, the terms "unit", "device", "part", and "module" described in the specification mean a unit for processing at least one function and operation, and can be implemented by hardware components or software components, and combinations thereof.

[0046] While the example embodiments are described as using a plurality of units to perform the example processes, it should be understood that the example processes can also be performed by one or more modules. Furthermore, it should be understood that the term controller / control unit refers to a hardware device that includes a memory and a processor and is specifically programmed to perform the processes described herein. The memory is configured to store modules and the processor is specifically configured to execute the modules to conduct one or more processes described further below.

[0047] Furthermore, the control logic of the present application can be implemented as non-transitory computer readable media on a computer readable medium, containing executable program instructions executed by a processor, controller, or the like. Examples of computer readable media include, but are not limited to, ROM, RAM, compact discs (CDs)-ROM, tape, floppy disks, flash memories, smart cards, and optical data storage devices. The computer readable medium can also be distributed over network coupled computer systems so that the computer readable medium is stored in a distributed fashion throughout the

[0048] The term "about" as used herein is understood as being within the normal tolerances of the art, for example within a range of 2 standard deviations of the mean. "About" can be understood as being within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the specified value. Unless the context clearly indicates otherwise, all numerical values provided herein are modified by the term "about".

[0049] The term "battery cell stack" herein refers to a combination of two or more battery cells arranged adjacent to each other in a stacked or layered configuration.

[0050] The term "busbar" herein refers to an electrically conductive element that collects or distributes electric current.

[0051] The term "inter-busbar" herein refers to a secondary or auxiliary busbar used to interconnect battery cell stacks, which realizes parallel or series electrical connection as needed.

[0052] The term "busbar holding device" herein refers to a structural assembly configured to support or secure a busbar in a fixed spatial relationship with respect to a battery cell stack.

[0053] The term "base plate" herein refers to a base or bottom plate of a battery housing on which a battery cell stack, busbar, or other components are disposed or mounted.

[0054] The term "cross member" herein refers to a reinforcing member or beam that extends across the battery cell stack in a direction perpendicular or transverse to the main arrangement of the battery cell stack.

[0055] The term "side support region" herein refers to a portion of the side wall or busbar holding device configured to provide mechanical support or alignment to the busbar or intermediate busbar.

[0056] Hereinafter, embodiments of the present application will be described with reference to Figures 1 to 10 be described in detail. Hereinafter, a left / right direction can be a first direction, a front / back direction can be a second direction, an up / down direction can be a third direction, and the first to third directions can be directions perpendicular to each other.

[0057] Figure 1 is an exploded perspective view of a battery pack according to an embodiment of the present application. Figure 2 is a perspective view of a battery case before a module of electrical components is installed according to an embodiment of the present application.

[0058] Figure 3 is a perspective view of a battery case in which a module of electrical components is installed according to an embodiment of the present application. Figure 4 is Figure 3 is an enlarged view of a portion "A" shown in FIG. 1. Figure 5 is Figure 3 is an enlarged view of a portion "B" shown in FIG. 1. Figure 6 is Figure 3 is an enlarged view of a portion "C" shown in FIG. 1.

[0059] Referring to Figures 1 to 6 , the battery pack 100 can include a battery case 200 in which a plurality of battery cell stacks 400 are accommodated, a module of electrical components 500, and a battery pack cover 600 coupled to the battery case 200 to cover the plurality of battery cell stacks 400 and the module of electrical components 500.

[0060] The battery case 200 can include a base plate 210 on which the plurality of battery cell stacks 400 are disposed, and a front member 220, a rear member 230, and side members 240 coupled to the base plate 210 along the periphery of the base plate 210, respectively.

[0061] The front member 220 can be disposed at one side of the base plate 210 in the second direction ("Y" direction), and the rear member 230 can be disposed at the opposite side of the base plate 210 in the second direction (a direction opposite to the "Y" direction).

[0062] The side members 240 can extend to connect the front member 220 and the rear member 230 at opposite sides of the base plate 210 in the first direction (i.e., the "X" direction and the direction opposite to the "X" direction).

[0063] The battery case 200 can accommodate the battery cell stack 400 through a space defined by the front member 220, the rear member 230, the side members 240, and the base plate 210.

[0064] A plurality of battery cell stacks 400 can be provided, which are spaced apart from each other in the first direction and arranged to face each other. For example, the plurality of battery cell stacks 400 can be provided as eight battery cell stacks 400. Among the plurality of battery cell stacks 400, four battery cell stacks 400 can be arranged at one side (the "X" direction) of the battery case 200 in the first direction with respect to a central region in the first direction, and among the plurality of battery cell stacks 400, the other four battery cell stacks 400 can be arranged at the opposite side (the direction opposite to the "X" direction) of the battery case 200 in the first direction with respect to the central region in the first direction. However, the number and arrangement of the battery cell stacks 400 are not limited thereto.

[0065] The battery case 200 can include a first spanning member 250 extending between the plurality of battery cell stacks 400 in the first direction in the second direction, and a plurality of second spanning members 260 extending between the plurality of battery cell stacks 400 in the second direction in the first direction to cross the first spanning member 250. The second spanning members 260 can be formed to be provided at opposite sides of each of the battery cell stacks 400 in the second direction.

[0066] Meanwhile, the electrical component module 500 can include a power relay assembly, a fuse assembly, and a battery management system (BMS). The power relay assembly can connect or disconnect power generated in the battery cell stack 400 to / from other components of the electric vehicle.

[0067] The fuse assembly can be configured to disconnect the electrical connection of the other components of the electrical component module or the battery cell stack 400 when there is an abnormality in the other components of the electrical component module or the battery cell stack 400.

[0068] The BMS can be configured to acquire information such as voltage, temperature, current, etc. of the battery cells 410 (see Figure 7 ) of the battery cell stack 400 to control the battery cell stack 400 or transmit the information to the power relay assembly.

[0069] Furthermore, the electrical component module 500 may include a busbar 510, an inter-busbar 520, and a communication busbar 530. Here, busbar 510 is a high-voltage busbar and may be configured such that a relatively large current or a relatively high voltage flows in the battery pack 100 according to this application. Busbar 510 may be connected to a power relay assembly.

[0070] Bus 510 can be connected to a high-voltage connector disposed in at least one of the regions on opposite sides of the battery housing 200 in the second direction. Bus 510 can supply power to other components of the vehicle (which are disposed on opposite sides of the battery pack 100 in the second direction). For this purpose, bus 510 can extend in the second direction.

[0071] The intermediate bus 520 can be configured to electrically connect a pair of battery cell stacks 400 arranged adjacent to each other in the second direction.

[0072] The communication bus 530 can be configured to connect the battery cell stack 400 to the BMS or to the power relay assembly.

[0073] Meanwhile, in the event of a fire inside the battery casing 200, the cover of the busbar 510 may be damaged when exposed to the fire, potentially leading to more significant thermal runaway of the battery pack 100. To prevent this, the busbar 510 of the battery pack 100 according to an embodiment of this application may extend along a second direction in the region between the plurality of battery cell stacks 400 in a first direction, rather than extending along the second direction on one side of the battery cell stacks 400 in a third direction.

[0074] To prevent the busbar 510 from being exposed to fire, its position needs to be secured. For this purpose, the battery housing 200 may include a busbar holding device 300 that secures the position of the busbar 510 between the first crossing member 250 and the substrate 210. The busbar holding device 300 may extend along a central region in a first direction of the substrate 210 between the front member 220 and the rear member 230.

[0075] like Figure 2 and Figure 3 As shown, the busbar holding device 300 can be joined to the substrate 210 and mounted on the substrate 210 during the manufacturing process of the battery pack 100. The busbar holding device 300 can be formed of a material that can be injection molded for easy joining to the substrate 210.

[0076] like Figure 5As illustrated, the busbar holding device 300 can include a base wall 310, a pair of side walls 320, a pair of busbar support walls 330, and a pair of spacers 340.

[0077] The base wall 310 can be fixed to the base plate 210. The pair of side walls 320 can extend from opposite sides of the base wall 310 in the first direction to one side of the third direction ("Z" direction), respectively.

[0078] The pair of busbar support walls 330 can protrude from the base wall 310 to one side of the third direction between the pair of side walls 320 to support the busbar 510.

[0079] The pair of spacers 340 can protrude from the base wall 310 to one side of the third direction between the pair of busbar support walls 330 to space the pair of busbars 510 apart from each other. The pair of spacers 340 can be arranged in parallel to each other.

[0080] More specifically, the pair of side walls 320 can accommodate the busbar 510 therebetween. To this end, a height at which each of the pair of side walls 320 extends from the base wall 310 to one side of the third direction can be greater than a height at which the busbar support wall 330 protrudes from the base wall 310 to one side of the third direction. In other words, the height of the busbar support wall 330 in the third direction can be less than the height of the side wall 320 in the third direction.

[0081] The side wall 320 can include a side connection region 321 connected to the base wall 310 and extending in the second direction, and a side support region 322 arranged in the second direction with the side connection region 321 interposed therebetween.

[0082] The side connection region 321 and the side support region 322 can be alternately arranged along the second direction. The side connection region 321 can connect a pair of side support regions 322 adjacent to each other in the second direction.

[0083] A height at which the side support region 322 extends from the base wall 310 to one side of the third direction can be higher than a height at which the side connection region 321 extends from the base wall 310 to one side of the third direction. In other words, the height of the side support region 322 in the third direction can be greater than the height of the side connection region 321 in the third direction.

[0084] Further, the side support region 322 can include a portion having a thickness in the first direction greater than a thickness of the side connection region 321 in the first direction. This can be to enhance rigidity of the side support region 322. Accordingly, the busbar 510 can be fixed by the busbar holding device 300 even when a region in which no side connection region 321 is provided in a region between the side support regions 322 is unable to support the busbar 510.

[0085] Meanwhile, the base wall 310 can extend from a central region of the substrate 210 in the first direction along the second direction.

[0086] The base wall 310 can include a base region 311 connected to the side wall 320 and the busbar support wall 330, and a protruding region 312 protruding from the base region 311 toward opposite sides of the first direction, respectively. The protruding region 312 can be a partial region of the base wall 310 that is engaged with the middle busbar 520 to support the middle busbar 520.

[0087] The middle busbar 520 can be disposed adjacent to a region provided between a pair of battery cell stacks 400 disposed adjacent to each other in the second direction. The middle busbar 520 is disposed as such because the middle busbar 520 is configured to electrically connect a pair of battery cell stacks 400 disposed adjacent to each other in the second direction.

[0088] The middle busbar 520 can extend along the second direction, and can include opposite end portions in the second direction. The opposite end portions of the middle busbar 520 can be engaged to the protruding region 312 of the base wall 310 by an engagement member "F". Here, the engagement member "F" can be configured to engage the opposite end portions of the middle busbar 520 with the protruding region 312.

[0089] The middle busbar 520 can be disposed between the busbar 510 and the base wall 310 in the third direction. This is because the middle busbar 520 can be disposed on the protruding region 312 of the base wall 310, and the busbar 510 can be seated on the busbar support wall 330 protruding from the base wall 310 toward one side in the third direction.

[0090] Figure 7 FIG. 1 is a perspective view of a battery cell stack according to an embodiment of the present application. Figure 8 FIG. 2 is an enlarged view illustrating a middle busbar, a connection terminal, and a busbar between battery cell stacks according to an embodiment of the present application.

[0091] Referring to Figure 7 and Figure 8 The battery cell stack 400 can include battery cells 410 extending in the first direction and arranged in the second direction, and end plates 420 provided on opposite sides of the battery cells 410 in the second direction to prevent swelling of the battery cells 410.

[0092] The battery cell stack 400 can include a sensing assembly 430 disposed at opposite sides of the battery cell 410 in the first direction, and a cover (not shown) covering the outer sides of the sensing assembly 430 in the first direction.

[0093] The sensing assembly 430 can include a plate 440, a sensing busbar 450 connected to the plate 440, and a sensing frame 460 supporting the plate 440 and the sensing busbar 450.

[0094] The plate 440 can be configured to extend from an area of one side of the sensing frame 460 in the third direction in the second direction, and can be attached to the sensing frame 460.

[0095] The sensing busbar 450 can be connected to the plate 440. The sensing busbar 450 can extend from the plate 440 to the opposite side of the third direction, and can be arranged to be spaced apart from each other in the second direction. The sensing busbar 450 can be electrically connected to the cell lead 411 (see Figure 9 ) of the battery cell 410.

[0096] The sensing frame 460 can be disposed at opposite sides of the battery cell 410 in the first direction to support the plate 440 and the sensing busbar 450.

[0097] The sensing assembly 430 can include a connection terminal 470 electrically connected to the sensing busbar 450. The connection terminal 470 can be connected to each of the sensing busbars 450 (among the plurality of sensing busbars 450 belonging to the battery cell stack 400) disposed at opposite ends in the second direction, and can protrude outward from the sensing busbar 450 in the first direction.

[0098] In addition, the connection terminal 470 can be configured to electrically connect the intermediate busbar 520 to the sensing busbar 450. Since the intermediate busbar 520 according to the embodiment of the present application can be disposed at opposite side areas in the third direction inside the battery case 200 (refer to Figure 2 ) to be coupled to the base wall 310, the connection terminal 470 can be disposed at opposite side areas in the third direction of the sensing assembly 430.

[0099] According to such a structure, the connection terminal 470 can be more easily coupled to the intermediate busbar 520 disposed adjacent to the base plate 210 inside the battery case 200, and information about the battery cell 410 of the battery cell stack 400 can be transmitted to the BMS through the intermediate busbar 520, or a signal for controlling the battery cell 410 can be received from the BMS.

[0100] Further, since the battery cell 410 extends in the first direction, the connection terminal 470 can protrude toward the central region of the substrate 210 (see Figure 5 ), so that the middle busbar 520 can be disposed at the central region of the battery case 200 in the first direction.

[0101] Meanwhile, as shown in Figure 8 , the second spanning member 260 can extend in the first direction between the opposite ends of the middle busbar 520 in the second direction.

[0102] Further, when the busbar 510, the middle busbar 520, and the protruding region 312 (see Figure 5 ) are viewed in a state spaced apart in the third direction, the busbar 510 can include a region having a curved shape to be farther away from the opposite ends of the middle busbar 520 in the second direction in the first direction.

[0103] For example, a joining member "F" for joining the opposite ends of the middle busbar 520 and the middle busbar 520 with the connection terminal 470 needs to be fixed by a tool. In order for the tool to be able to fix the joining member "F", the tool needs to be inserted from one side in the third direction toward the joining member "F", and for this, the opposite ends of the middle busbar 520 and the region of the connection terminal 470 in the third direction need to be open to one side in the third direction.

[0104] To this end, the region of the busbar 510 adjacent to each of the opposite ends of the middle busbar 520 in the second direction can include a region having a curved shape so as to be farther away from each of the opposite ends of the middle busbar 520 in the first direction.

[0105] With this structure, in the process of manufacturing the battery pack 100 (see Figure 1 ), the busbar 510 and the middle busbar 520 are disposed on the busbar holding device 300, the connection terminal 470 is disposed to be connected to the opposite ends of the middle busbar 520, and then the base wall 310 (see Figure 5 ) of the busbar holding device 300, the middle busbar 520, and the connection terminal 470 can be more easily joined to each other by the joining member "F" and the tool.

[0106] Figure 9 is a cross-sectional view of a busbar, a middle busbar, a connection terminal, and a substrate disposed between battery cell stacks according to an embodiment of the present application.

[0107] Referring to Figure 9 , the base wall 310 can be joined to the substrate 210, and the middle busbar 520 and the connection terminal 470 can be connected to each other on the protruding region 312 (see Figure 5 ) of the base wall 310 by the joining member "F".

[0108] For example, the intermediate busbar 520 can be disposed at a region opposite to the busbar 510 in the third direction. When the busbar 510 and the intermediate busbar 520 are observed in a state spaced apart in the second direction, the intermediate busbar 520 and the busbar 510 can extend in directions perpendicular to each other.

[0109] More specifically, the intermediate busbar 520 can have a length in the first direction greater than a length in the third direction, and the busbar 510 can be spaced apart from the intermediate busbar 520 in the third direction such that the length thereof in the third direction is greater than the length thereof in the first direction.

[0110] According to such a structure, while maintaining a distance between the intermediate busbar 520 and the busbar 510, a space utilization rate can be relatively optimized at a region on one side in the third direction of the second spanning member 260.

[0111] Further, since the substrate 210 can include the cooling passage 211 inside thereof, this can prevent an increase in temperature of the busbar 510 and the intermediate busbar 520 arranged relatively close to the substrate 210. Accordingly, safety of the battery pack 100 can be improved.

[0112] Further, the first spanning member 250 can be disposed between the pair of spacers 340. The first spanning member 250 can be configured to insulate two regions separated from each other in the first direction by the first spanning member 250 in a region (see Figure 2 ) of the battery case 200.

[0113] Due to the first spanning member 250 and the second spanning member 260 (see Figure 8 ), even if a fire occurs in any one of the plurality of battery cell stacks 400, a flame or gas can be prevented from spreading to another adjacent battery cell stack 400, and thus thermal runaway of the battery pack 100 (see Figure 1 ) can be prevented.

[0114] Figure 10 is a flowchart illustrating a method of manufacturing a battery pack according to an embodiment of the present application.

[0115] Referring to Figure 1 and Figure 10 , the method of manufacturing the battery pack 100 can include a busbar installation operation S10, a cell installation operation S20, a spanning member installation operation S30, and a battery pack cover joining operation S40.

[0116] The busbar installation operation S10 can be an operation of installing the busbar 510 to the busbar holding device 300 of the battery case 200.

[0117] The busbar installation operation S10 can include fixing the busbar holding device 300 for fixing the busbar 510 to the base plate 210, and then seating the busbar 510 on the busbar holding device 300.

[0118] Further, the busbar installation operation S10 can include fixing the busbar holding device 300 for fixing the busbar 510 to the base plate 210, and installing the intermediate busbar 520 for electrical connection of the battery cell stack 400 to the battery case 200.

[0119] Further, the busbar installation operation S10 can include installing the remaining components of the battery case 200 other than the busbar 510 and the intermediate busbar 520 of the battery component module 500 inside the battery case 200.

[0120] After the busbar installation operation S10, the cell installation operation S20 can be an operation of installing a plurality of battery cell stacks 400 to the battery case 200 such that the plurality of battery cell stacks 400 face each other with the busbar 510 interposed therebetween in the first direction.

[0121] For example, the battery cell stack 400 can be in a state in which, after the battery cell 410 extending in the first direction and arranged in the second direction are stacked with the cooling plate or the surface pressure member, the end plate 420 is stacked on opposite sides of the battery cell 410 in the second direction.

[0122] Further, the battery cell stack 400 can be in a state in which, after the end plate 420 is stacked, the sensing assembly 430 is assembled on opposite sides of the battery cell 410 in the first direction, and the cell lead 411 (see Figure 9 ) is welded to the sensing busbar 450. Thereafter, a cover for covering the battery cell 410 or the sensing assembly 430 can be assembled on the outside of the sensing assembly 430 in the first direction.

[0123] The cell installation operation S20 can include electrically connecting the connection terminal 470 of the battery cell stack 400 and the intermediate busbar 520. The cell installation operation S20 can include connecting the connection terminal 470 and the intermediate busbar 520, and joining the busbar holding device 300, the intermediate busbar 520, and the connection terminal 470 such that the electrical connection of the busbar holding device 300, the intermediate busbar 520, and the connection terminal 470 is maintained.

[0124] After the cell installation operation S20, the spanning component installation operation S30 can be an operation of installing the first spanning component 250 (which extends in the second direction) and the second spanning component 260 (which is disposed in a direction crossing the first spanning component 250) on the battery case 200 between the plurality of battery cell stacks 400.

[0125] More specifically, the spanning component installation operation S30 can include installing the first spanning component 250 inside the battery case 200 between the pair of spacers 340, and installing the second spanning component 260 inside the battery case 200 between the battery cell stack 400 adjacent to each other in the second direction.

[0126] Here, the installation order of the second spanning component 260 can precede the first spanning component 250, but the present application is not limited thereto.

[0127] After the spanning component installation operation S30, the battery pack cover joining operation S40 can be an operation of joining the battery pack cover 600 to the battery case 200.

[0128] According to the method of manufacturing the battery pack 100 described above, since the battery cell stack 400 can be assembled in the stacking unit and installed inside the battery case 200 in which the electrical component module 500 such as the busbar 510 or the intermediate busbar 520 is installed, the manufacturing process of the battery pack 100 becomes relatively simplified, so that the production efficiency of the battery pack 100 can be improved.

[0129] According to the technology of the present application, since the busbar holding device fixes the busbar, it is possible to prevent the busbar from being exposed inside the battery case, so that even if a fire occurs in the battery cell, the heat runaway spread due to the busbar can be prevented.

[0130] In addition, according to the technology of the present application, since the busbar holding device does not require a separate component for fixing the busbar, the production efficiency of the battery pack can be improved by reducing the cost due to the omission of the separate component.

[0131] In addition, according to the technology of the present application, since the busbar and the intermediate busbar are fixed at a position adjacent to the substrate, the cooling passage provided inside the substrate can prevent the temperature of the busbar and the intermediate busbar from rising.

[0132] In addition, according to the technology of the present application, since the curved shape of the busbar, when the connection terminals of the intermediate busbar and the battery cell stack are joined to each other, the joining member and the tool can be easily inserted, so that the production efficiency of the battery pack can be improved.

[0133] In addition, various effects directly or indirectly confirmed through the present application document can be provided.

[0134] The above description is a simple exemplary explanation of the technical spirit of the present application, and those skilled in the art to which the present application pertains can make various modifications and changes without departing from the essential characteristics of the present application.

[0135] Therefore, the embodiments disclosed in this application are not intended to limit the technical spirit of the application, but to describe the technical spirit of the application, and the scope of the technical spirit of the application is not limited by the described embodiments. The protection scope of the application should be interpreted by the claims, and all the technical spirits in the equivalent scope should be interpreted as included in the scope of the application.

Claims

1. A battery pack comprising: Battery casing; Multiple battery cell stacks are configured to be housed inside a battery casing and arranged to be spaced apart from each other in a first direction; as well as A busbar that extends between multiple battery cell stacks along a second direction that intersects the first direction; The battery casing includes: A substrate on which the plurality of battery cell stacks are configured to be disposed; A first spanning component extends along a second direction between multiple battery cell stacks; A busbar holding device configured to fix the position of the busbar between a first crossing member and a substrate.

2. The battery pack of claim 1, wherein, The busbar holding device includes: A base wall, which is fixed to the substrate; and A pair of sidewalls extending from the base wall toward a third direction, the third direction intersecting the first and second directions, the pair of sidewalls accommodating the busbar.

3. The battery pack of claim 2, wherein, The busbar holding device further includes a busbar support wall that protrudes from the base wall in a third direction between a pair of sidewalls and supports the busbar.

4. The battery pack of claim 3, wherein, The height of the busbar support wall in the third direction is less than the height of the side wall in the third direction.

5. The battery pack according to claim 3, further comprising an intermediate busbar, the intermediate busbar being configured to electrically connect the battery cell stacks arranged side-by-side in a second direction; wherein The base wall is configured to support the intermediate busbar.

6. The battery pack of claim 5, wherein, The base wall includes: The base region, which connects to the sidewalls and the busbar support wall; and The protruding area extends from the base area toward the battery cell stack and is connected to the intermediate busbar.

7. The battery pack of claim 6, wherein, The intermediate busbar extends along a second direction and includes two opposite ends in the second direction; The protruding areas are joined to the opposite ends of the intermediate busbar.

8. The battery pack according to claim 7, further comprising: The second crossing component extends along the first direction and intersects the first crossing component between the two opposite ends of the intermediate busbar.

9. The battery pack according to claim 7, further comprising: A connecting member that joins the opposite ends of the intermediate busbar to the protruding area; When the busbar and the intermediate busbar are viewed in a state of being spaced apart along a third direction, the busbar includes regions that are bent to become more distant from the opposite ends of the intermediate busbar in a first direction.

10. The battery pack of claim 5, wherein, The intermediate busbar is positioned between the busbar and the base wall.

11. The battery pack of claim 5, wherein, When observing the busbar and intermediate busbar in a state of separation along the second direction, The length of the intermediate busbar in the first direction is greater than its length in the third direction. The busbar is spaced apart from the intermediate busbar in the third direction, such that the length of the busbar in the third direction is greater than its length in the first direction.

12. The battery pack of claim 5, wherein, The battery cell stack includes: Battery cells, which extend along a first direction and are arranged in a second direction; and A sensing component is disposed on one side of the battery cell in a first direction and is electrically connected to the intermediate bus.

13. The battery pack of claim 12, wherein, The connection terminal is located in the area on the opposite side of the sensing component in the third-party upward direction.

14. The battery pack of claim 2, wherein, Each of the sidewalls includes: The side connection region extends along the second direction; and A side support region is arranged in a second direction with a side connection region between the side support regions, the height of the side support region in the third direction being greater than the height of the side connection region in the third direction, and supports the busbar.

15. The battery pack of claim 14, wherein, The side support region includes a portion whose thickness in the first direction is greater than the thickness of the side connection region in the first direction.

16. The battery pack of claim 1, wherein, The substrate includes cooling channels inside the substrate.

17. A method of manufacturing a battery pack, the method comprising: Install the busbar into the battery housing; Multiple battery cell stacks are installed onto a battery casing such that the multiple battery cell stacks face each other with a busbar between them; A first crossing component and a second crossing component are installed between multiple battery cell stacks. Attach the battery pack cover to the battery housing.

18. The method of claim 17, wherein, Installing the busbar to the battery housing includes: The busbar holding device for fixing the busbar is fixed to the base plate; The busbar is placed on the busbar retaining device.

19. The method of claim 17, wherein, Installing the busbar to the battery housing includes: The busbar holding device for fixing the busbar is fixed to the base plate; The intermediate busbar used for electrical connections of the battery cell stack is installed to the battery housing.

20. The method of claim 19, wherein, Installing multiple battery cell stacks into a battery housing includes: Electrically connect the intermediate busbar to the connection terminals of the battery cell stack.

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