Secondary battery, apparatus for manufacturing secondary battery, and method for manufacturing secondary battery

Abstract

The invention relates to a secondary battery, an apparatus for manufacturing the secondary battery, and a method for manufacturing the secondary battery. The secondary battery includes an electrode assembly, and a case including a main body portion accommodating the electrode assembly, a cap covering an opening of the main body portion, and a sealing portion formed at a position where an outer surface of the main body portion and an outer surface of the cap come into contact with each other, thereby sealing the electrode assembly in the case. The sealing portion includes: a top sealing portion extending in a first direction from an upper surface of the housing; a plurality of side sealing portions, each of the plurality of side sealing portions extending from a side surface of the housing in a second direction intersecting with the first direction or in a direction opposite to the second direction; when the top seal portion and the plurality of side seal portions are folded in a third direction intersecting the first direction and the second direction, the corner seal portions are folded in the first direction.

Description

Technical Field

[0001] This disclosure relates to secondary batteries, apparatus for manufacturing secondary batteries, and methods for manufacturing secondary batteries. Background Technology

[0002] Unlike primary batteries, which are not designed for (re)charging, secondary (or rechargeable) batteries are designed to discharge and be recharged. Low-capacity secondary batteries are used in portable small electronic devices such as smartphones, feature phones, laptops, digital cameras, and camcorders, while high-capacity secondary batteries are widely used as power sources for driving motors in hybrid and electric vehicles, as well as for storing electricity (e.g., household and / or utility-scale power storage). A secondary battery typically includes an electrode assembly containing positive and negative electrodes, a housing that houses the electrode assembly, and electrode terminals connected to the electrode assembly.

[0003] Flexible printed circuit boards (FPCBs) can be electrically connected to the electrodes of the electrode assembly in a secondary battery. In terms of energy density, it is advantageous for the path of the FPCB to extend near the housing containing the electrode assembly. However, in pouch cells, the housing and cover are sealed by welding, and the welded sealing portion extends beyond the housing. Therefore, the FPCB cannot extend in a straight line adjacent to the housing. Consequently, the path of the FPCB becomes longer to bypass the sealing portion. To address this issue, it may be necessary to increase the energy density by reducing the overall length of the battery pack.

[0004] The information disclosed in this background section is intended to enhance the understanding of the background of this disclosure, and therefore may contain information that does not constitute related (or prior art). Summary of the Invention

[0005] This disclosure provides a secondary battery in which the FPCB connected to the lead terminal can extend in a straight line along the periphery of the housing.

[0006] This disclosure also provides an apparatus for manufacturing a secondary battery, the apparatus being capable of performing a process of folding a sealing portion (step) formed during the manufacturing process of the secondary battery.

[0007] This disclosure further provides a method for manufacturing a secondary battery, the method including a process of folding a sealing portion to ensure that the FPCB extends along its path.

[0008] These and other aspects and features of this disclosure will be described in, or will become apparent from, the following description of embodiments of this disclosure.

[0009] A secondary battery according to an embodiment of the present disclosure includes an electrode assembly and a housing. The housing includes: a main body portion for receiving the electrode assembly; a cover for covering an opening in the main body portion; and a sealing portion formed at the contact point between an outer surface of the main body portion and an outer surface of the cover, thereby sealing the electrode assembly within the housing. The sealing portion includes: a top sealing portion extending from an upper surface of the housing in a first direction; a plurality of side sealing portions, each of the plurality of side sealing portions extending from a side surface of the housing in a second direction intersecting the first direction or in a direction opposite to the second direction; and a corner sealing portion folding in the first direction when the top sealing portion and the plurality of side sealing portions are folded upward in a third direction intersecting the first and second directions.

[0010] According to one embodiment of this disclosure, the corner sealing portion can be folded in a direction opposite to the second direction.

[0011] According to one embodiment of this disclosure, the corner sealing portion may be placed on the top sealing portion.

[0012] According to one embodiment of the present disclosure, the top sealing portion and a plurality of side sealing portions can be folded upward along a plurality of folding regions in a third direction. The plurality of folding regions may include a first folding region, a second folding region, and a third folding region. The plurality of side sealing portions are folded upward along the first folding region in a third direction, the second folding region extends from the first folding region, and the top sealing portion is folded upward along the third folding region in a third direction.

[0013] According to one embodiment of the present disclosure, the corner sealing portion may include a plurality of corner sealing portions, and the plurality of folding regions may further include: a fourth folding region, wherein the plurality of corner sealing portions are folded along the fourth folding region in a second direction or in a direction opposite to the second direction after having been folded upward along the second folding region in a third direction; and a fifth folding region, wherein when each of the plurality of corner sealing portions is folded along the fourth folding region, the fifth folding region is folded within the plurality of corner sealing portions.

[0014] According to one embodiment of this disclosure, the fourth folding region may be located above the third folding region in a first direction.

[0015] According to one embodiment of this disclosure, the fifth fold region can extend from the upper edge of the sealing portion to the second fold region.

[0016] According to one embodiment of the present disclosure, each of the plurality of corner sealing portions can be folded in a first direction by folding along the fourth folding region and the fifth folding region.

[0017] According to one embodiment of the present disclosure, a first lead wire connected to a plurality of first electrode terminals of an electrode assembly and a second lead wire connected to a plurality of second electrode terminals of an electrode assembly can extend in a first direction, and each of the first lead wires and the second lead wires can also be folded upward in a third direction when the top sealing portion is folded upward in a third direction, and then folded in the opposite direction to the third direction.

[0018] According to one embodiment of this disclosure, the first lead terminal and the second lead terminal can be electrically connected to a flexible printed circuit board (FPCB), and the FPCB can extend in a second direction.

[0019] An apparatus for manufacturing a secondary battery according to an embodiment of the present disclosure includes: a guide block that fixes a housing of the secondary battery, the housing including a main body portion for receiving an electrode assembly, a cover covering an opening in the main body portion to seal the electrode assembly; and a sealing portion where an outer surface of the main body portion and an outer surface of the cover contact each other to seal the electrode assembly in the housing; a push block configured to apply pressure to the housing on a side opposite to the guide block; and a roller configured to rotate on a top sealing portion located on an upper surface of the housing and fold the top sealing portion.

[0020] According to one embodiment of this disclosure, the guide block may include: a first guide block supporting at least a portion of the lower surface of the housing in a first direction; and a second guide block supporting at least a portion of the side surface of the housing in a direction opposite to the second direction, and the push block may include: a first push block configured to press the upper portion of the housing in a direction opposite to the first direction on a side opposite to the first guide block to bend the top sealing portion; and a second push block configured to press the side portion of the housing in a second direction on a side opposite to the second guide block to fold over each of a plurality of side sealing portions on the respective side surface of the housing.

[0021] According to one embodiment of this disclosure, the width of the first pressing block in the second direction may be smaller than the width of the top sealing portion in the second direction.

[0022] According to one embodiment of the present disclosure, the roller may include a first roller and a second roller, which rotate from opposite ends of the top sealing portion to the central region of the top sealing portion to fold the top sealing portion.

[0023] According to one embodiment of this disclosure, a method for manufacturing a secondary battery includes an electrode assembly and a housing. The housing includes a main body portion for receiving the electrode assembly, a cover covering an opening in the main body portion, and a sealing portion formed at the contact point between the outer surface of the main body portion and the outer surface of the cover to seal the electrode assembly within the housing. The sealing portion includes a top sealing portion extending from the upper surface of the housing in a first direction and a plurality of side sealing portions extending from the side surfaces of the housing in a second direction intersecting the first direction or in a direction opposite to the second direction. The method includes: folding each of the plurality of side sealing portions of the sealing portion upward toward the housing in a third direction intersecting the second direction; applying pressure to the top sealing portion of the sealing portion in a direction opposite to the first direction; and folding the top sealing portion upward in a third direction by rotational movement of a plurality of rollers to fold corner sealing portions of the sealing portion in the second direction and in a direction opposite to the second direction.

[0024] According to one embodiment of this disclosure, the secondary battery may further include: a first lead tab, a plurality of first electrode tabs connected to an electrode assembly and extending in a first direction; and a second lead tab, a plurality of second electrode tabs connected to an electrode assembly and extending in the first direction. A corner sealing portion folding a sealing portion in a second direction and a direction opposite to the second direction may include: folding each of the first and second lead tabs in said three directions when the top sealing portion is folded upwards. A method of manufacturing the secondary battery may further include: folding the already folded first and second lead tabs in a direction opposite to the third direction; and electrically connecting the first and second lead tabs to a flexible printed circuit board (FPCB) extending in the second direction after folding the first and second lead tabs.

[0025] According to one embodiment of this disclosure, the FPCB can extend from the first lead tab and the second lead tab along the upper surface of the housing.

[0026] According to one embodiment of this disclosure, multiple rollers can press the upper end of the top sealing portion by about 1.3 mm to 1.7 mm or about 70% to 80% of the height of the upper end of the top sealing portion while moving.

[0027] According to one embodiment of this disclosure, the corner sealing portion can be folded to be adjacent to the upper surface of the housing.

[0028] According to one embodiment of this disclosure, the top sealing portion and the side sealing portion can be folded upward along a plurality of folding regions in a third direction, respectively. The plurality of folding regions may include a first folding region, a second folding region, and a third folding region. The plurality of side sealing portions are folded upward along the first folding region in a third direction, the second folding region extends from the first folding region, and the top sealing portion is folded upward along the third folding region in a third direction. The plurality of folding regions may further include: a fourth folding region, in which each of the plurality of corner sealing portions is folded in a direction opposite to the second direction after having already been folded upward along the second folding region in a third direction; and a fifth folding region, in which each of the plurality of corner sealing portions is folded within the plurality of corner sealing portions along the fifth folding region when each of the plurality of corner sealing portions is folded along the fourth folding region.

[0029] According to some embodiments of this disclosure, the sealing portion at the corner of the housing can be folded so that the sealing portion does not obstruct the path of the FPCB along its extension, thereby shortening the overall length of the battery pack.

[0030] According to some embodiments of this disclosure, the volume of the battery pack can be reduced, thereby increasing the energy density.

[0031] However, the aspects and features of this disclosure are not limited to those described above, and those skilled in the art will clearly understand from the detailed description below that other aspects and features not mentioned will be apparent. Attached Figure Description

[0032] The following accompanying drawings illustrate embodiments of the present disclosure and, together with the detailed description of the present disclosure, further describe aspects and features of the present disclosure. Therefore, the present disclosure should not be construed as limited to the drawings.

[0033] Figure 1 This illustrates how the electrode assembly of a secondary battery is integrated into the housing according to one embodiment of the present disclosure.

[0034] Figure 2 This is a perspective view of a secondary battery according to an embodiment of the present disclosure.

[0035] Figure 3 This is an exploded perspective view of the casing, FPCB, and PCM of a secondary battery according to an embodiment of the present disclosure.

[0036] Figure 4 This illustration shows a secondary battery whose sealed portion has been unfolded, according to one embodiment of the present disclosure.

[0037] Figure 5 A folded area on a cover including a sealing portion is shown according to an embodiment of the present disclosure.

[0038] Figure 6This is a schematic diagram of an apparatus for manufacturing a secondary battery according to an embodiment of the present disclosure.

[0039] Figure 7 This illustrates how a curved portion is formed on the top sealing portion by a first push block according to one embodiment of the present disclosure.

[0040] Figure 8 The process for manufacturing a secondary battery according to one embodiment of the present disclosure is shown.

[0041] Figure 9 A folded side sealing portion is shown according to one embodiment of the present disclosure.

[0042] Figure 10 This illustrates how the top sealing portion is pressed by a first push block according to one embodiment of the present disclosure.

[0043] Figure 11 The diagram shows a folded portion that has been folded by the first and second rollers according to an embodiment of the present disclosure.

[0044] Figure 12 An FPCB connected to a lead wire tab is shown according to one embodiment of the present disclosure.

[0045] Figure 13 This illustrates how a folded portion is formed when the top sealing portion and the side sealing portion are folded in a first direction, according to an embodiment of the present disclosure.

[0046] Figure 14 A folded portion comprising a first folded portion, a second folded portion, and a third folded portion is shown according to an embodiment of the present disclosure.

[0047] Figure 15 This demonstrates how a traditional FPCB can be extended.

[0048] Figure 16 This illustrates how an FPCB extends according to one embodiment of the present disclosure. Detailed Implementation

[0049] In the following, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The terms or words used in this specification and claims should not be construed as having their usual or dictionary meaning, and should be interpreted in a way consistent with the technical spirit of the present disclosure, based on the principle that the inventor can be his / her own lexicographer to appropriately define the concepts of the terms in order to best describe his / her invention. Therefore, the embodiments described in this specification and the configurations shown in the drawings are merely some embodiments of the present disclosure and do not represent all ideas, aspects, and features of the present disclosure. Accordingly, it should be understood that various equivalents and modifications may exist that can replace or modify the embodiments described herein at the time of filing this application.

[0050] Furthermore, it will be further understood that, if used in this specification, the terms “comprising” and / or “including” specify the presence of the stated features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0051] In addition, for clarity, the dimensions of various components, layers, etc., may be enlarged in the accompanying drawings. The same reference numerals are used to label identical parts.

[0052] Referring to two compared elements, features, etc., as “identical” may mean that they are “substantially identical.” Therefore, the phrase “substantially identical” can include cases with deviations considered low in the art, such as less than 5%. Additionally, when a parameter is said to be consistent in a given region, this may mean that it is consistent in terms of average value.

[0053] It will be understood that although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. Therefore, and in the context unless otherwise specified, the first element may also be referred to as the second element.

[0054] Throughout this specification, unless otherwise stated, each element may be singular or plural.

[0055] The arrangement of any element "above (or below)" or "on (below)" another element can mean that the arbitrary element can contact the upper (or lower) surface of the element, and that the other element can be located between the element and any element arranged on (or below) the element.

[0056] Furthermore, it will be understood that when a component is referred to as "connected," "linked," or "attached" to another component, the components may be directly "connected," "linked," or "attached" to each other, or other components may be "intermediate" between the components. It will also be understood that when an element is referred to as "electrically connected" to another element, it may be directly connected to other elements or there may be intermediary elements.

[0057] Throughout this specification, when “A and / or B” is stated, it means A, B, or A and B, unless otherwise stated to the contrary. In other words, “and / or” includes any or all combinations of the listed items. When “C to D” is stated, it means C and below, unless otherwise stated.

[0058] The terminology used herein is for the purpose of describing embodiments of this disclosure and is not intended to limit this disclosure.

[0059] Figure 1 This illustrates how the electrode assembly 20 of a secondary battery 100 according to an embodiment of the present disclosure is provided in a housing. Reference Figure 1 The electrode assembly 20 can be located within the internal space formed by combining the main body portion 110 and the cover 120. A sealing portion can be disposed in the area where the cover 120 and the main body portion 110 contact each other. The sealing portion can include a top sealing portion, a side sealing portion, and a corner sealing portion, all of which are formed around the periphery of the housing. Here, the direction in which the top sealing portion 120b extends from the housing (e.g., its upper surface) can be defined as a first direction D1, the direction in which the side sealing portion 120a extends from the housing (e.g., its side surface) can be defined as a second direction D2, and the direction in which the top sealing portion 120b and the side sealing portion 120a are folded can be defined as a third direction D3.

[0060] Generally, a pouch-type secondary battery 100 may include an electrode assembly 20 and a housing containing the electrode assembly 20. The housing may be pouch-shaped. The electrode assembly 20 may include a positive electrode plate, such as a first electrode plate 11, and a negative electrode plate, such as a second electrode plate 12. A separator 13 may be located between the electrode plates 11 and 12. In one example, the first electrode plate 11 may be a negative electrode plate, and the second electrode plate 12 may be a positive electrode plate. In other examples, the first electrode plate 11 may be a positive electrode plate, and the second electrode plate 12 may be a negative electrode plate.

[0061] The first electrode plate 11 may include a first electrode tab 11-1 electrically connected to an uncoated portion of the first electrode. The second electrode plate 12 may include a second electrode tab 12-1 electrically connected to an uncoated portion of the second electrode. The first electrode tab 11-1 and the second electrode tab 12-1 may be electrically connected by soldering to the first lead tab 111-1 and the second lead tab 111-2, respectively. A tab film for insulation from the housing may be attached to the first lead tab 111-1 and the second lead tab 111-2.

[0062] After the electrode assembly 20 is housed in the housing, the sealing portions at the edges of the housing can be moved to contact each other to seal the housing. Here, the housing can be sealed with a bonding pad membrane placed between the sealing portions. The bonding pad membrane can be attached to each of the first electrode bonding pad 11-1 and the second electrode bonding pad 12-1.

[0063] The sealing portion of the housing can be made of a thermoplastic material, and the thermoplastic layers can be bonded together to seal the housing. Because thermoplastic materials typically do not adhere well to metals, thin-film shaped contact plates can be attached to the electrode contacts and fused to the housing.

[0064] refer to Figure 1 The electrode assembly 20 can be formed by stacking cell units 10. Each cell unit 10 includes a first electrode plate 11 having a first electrode terminal 11-1, a second electrode plate 12 having a second electrode terminal 12-1, and a separator 13 between the first electrode plate 11 and the second electrode plate 12. Thus, the electrode assembly 20 can be an assembly formed by a stacking process. The electrode plates and electrode terminals can be formed in the shape of thin plates or films. The electrode assembly 20 can be a Z-stacked electrode assembly formed by positioning the first electrode plate 11 and the second electrode plate 12 onto the side surface of the separator 13 folded into a Z-shape. However, the shape of the electrode assembly 20 is not limited in this disclosure.

[0065] Multiple electrode assemblies 20 can be stacked with their long sides adjacent to each other and housed separately inside the housing. The number of electrode assemblies 20 is not limited in this disclosure.

[0066] The first electrode terminal 11-1 and the second electrode terminal 12-1 can be located on the same side of the electrode assembly 20. For example, the first electrode terminal 11-1 and the second electrode terminal 12-1 can be formed on the same side of the electrode assembly 20, parallel to the stacking direction of the unit cells 10 of the electrode assembly 20. In other embodiments, the first electrode terminal 11-1 and the second electrode terminal 12-1 can extend from different sides of the electrode assembly 20. For example, the first electrode terminal 11-1 can be placed on the left side of the electrode assembly 20 in each side parallel to the stacking direction of the unit cells 10 of the electrode assembly 20, and the second electrode terminal 12-1 can be disposed on the right side of the electrode assembly 20. For convenience, based on Figure 1 The secondary battery 100 shown is referred to as the left and right sides, and the positions of each component can change when the secondary battery 100 is rotated left and right or up and down.

[0067] The electrode assembly 20 can be housed in a housing together with the electrolyte. In some embodiments, the first lead terminal 111-1 and the second lead terminal 111-2 can be respectively connected to the first electrode terminal 11-1 of the first electrode plate 11 and the second electrode terminal 12-1 of the second electrode plate 12 of the electrode assembly 20. The first current collector portion and the second current collector portion can be respectively soldered and connected to the first lead terminal 111-1 and the second lead terminal 111-2.

[0068] The strip 15 may be attached to the front surface of the electrode assembly 20 perpendicular to the stacking direction of the cell 10. For example, the strip 15 may be attached to an edge of the electrode assembly 20 perpendicular to the stacking direction of the cell 10, adjacent to a portion of the first electrode tab 11-1 or the second electrode tab 12-1 on the front surface of the electrode assembly 20. In other embodiments, the strip 15 may be attached to an edge of the electrode assembly 20 perpendicular to the stacking direction of the cell 10, adjacent to a portion of the first electrode tab 11-1 or the second electrode tab 12-1 on the rear surface of the electrode assembly 20. The front or rear surface of the electrode assembly 20 is referred to as such to distinguish the two surfaces of the electrode assembly 20 that are perpendicular to the stacking direction of the cell 10. Here, "front or rear" does not necessarily mean a surface facing forward or backward. The front or rear surface of the electrode assembly 20 may be referred to as the first or second surface of the electrode assembly 20, which is perpendicular to the stacking direction of the cell 10.

[0069] Examples are provided above. Figure 1 The electrode assembly 20 is formed by the stacking process described above. However, this disclosure is not limited to such an embodiment. In another example, the electrode assembly 20 can be manufactured in the shape of an electrode core.

[0070] Figure 2 This is a perspective view of a secondary battery 100 according to an embodiment of the present disclosure. Figure 3 This is an exploded perspective view of the casing, FPCB 130, and powertrain control module (PCM) 140 of a secondary battery 100 according to an embodiment of the present disclosure. (See reference) Figure 2 and Figure 3 The lead terminal 111, including the first and second lead terminals which have been folded twice, can be electrically connected to the FPCB 130, and the FPCB 130 can extend in the second direction D2. As shown, the FPCB 130 can contact the housing. Although the extension path changes as the FPCB 130 is provided along the housing in this example, the FPCB 130 extends in a straight line in the second direction D2.

[0071] A pair of lead tabs 111 protruding from the electrode assembly 20 and the housing can contact the FPCB 130 on the upper surface of the housing for electrical connection, and the FPCB 130 can be connected to the PCM 140 on the upper surface of the housing. Here, when the lead tabs 111 are folded toward the upper surface of the housing, the lead tabs 111 can be electrically connected to the FPCB 130 on the upper surface of the housing. The FPCB 130 can extend from the lead tabs 111 along the upper surface of the housing. When the pair of lead tabs 111 are spaced apart from each other as in this example, the PCM 140 can be located between the lead tabs 111 and connected to the FPCB 130.

[0072] FPCB 130 may have at least a portion that contacts the housing. The sealing portion may be folded at the corner sealing portion 120c to form a folded portion F folded toward the upper surface of the housing. With this configuration, FPCB 130 can extend beyond the sealing portion while contacting the housing.

[0073] Figure 4 A secondary battery 100 having a sealed portion is shown according to an embodiment of the present disclosure. Reference Figure 4 A sealing portion formed by combining the main body portion 110 and the cover 120 can be formed at the periphery of the main body portion 110 before it is folded. A portion of the lead terminal piece 111 extending out of the housing can be positioned together with the top sealing portion 120b. Here, the sealing portion can be along... Figure 5 The folded area shown is folded.

[0074] Figure 5 This is a view of the sealing portion and the folded area on the cover 120 according to an embodiment of the present disclosure. (See reference...) Figure 5 The sealing portion formed at the periphery of the cover 120 can be folded in the third direction D3, thereby contacting or being adjacent to the main body portion 110. Specifically, the top sealing portion 120b can be folded in the third direction D3 along the third folding region 123, and the side sealing portion 120a can be folded in the third direction D3 along the first folding region 121. Here, when the top sealing portion 120b and the side sealing portion 120a are folded, a pair of corner sealing portions 120c can form overlapping surfaces and are folded along the fourth folding region 124 and the fifth folding region 125 adjacent to the upper surface of the housing in the second direction D2 and in the direction opposite to the second direction D2. In some embodiments, when the corner sealing portions 120c are folded toward the upper surface of the housing, the fifth folding region 125 and the second folding region 122 can overlap each other. Through this overlap, the two layers of the folded portion F can become part of the corner sealing portion 120c. Here, the overlapping area formed when the corner sealing portion 120c is folded can be located on the top sealing portion 120b, which has also been folded.

[0075] More specifically, the folding portion may include a first folding region 121, a fourth folding region 124, a fifth folding region 125, a second folding region 122, and a third folding region 123. A side sealing portion 120a folds along the first folding region 121 in a third direction D3. A corner sealing portion 120c folds along the fourth folding region 124 to be adjacent to the upper surface of the housing. The corner sealing portion 120c folds along the fifth folding region 125 and the second folding region 122 within this region. A top sealing portion 120b folds along the third folding region 123 in a third direction D3. Here, the second folding region 122 may be formed on the same line as the first folding region 121 in a first direction D1. In some embodiments, the fifth folding region 125 may extend across the corner sealing portion 120c, and one end of it may contact the ends of the second folding region 122 and the fourth folding region 124. In some embodiments, the fifth folding region 125 may extend from the upper edge of the sealing portion and across the corner sealing portion 120c, and one end of it may contact the ends of the second folding region 122 and the fourth folding region 124. Additionally, the fourth folding region 124 may be positioned higher than the third folding region 123 in the first direction D1.

[0076] Figure 6 This is a schematic diagram of an apparatus 200 for manufacturing a secondary battery 100 according to an embodiment of the present disclosure. Figure 7 This illustration shows how a curved portion 126 is formed on the top sealing portion 120b by a first pusher block 202 according to an embodiment of the present disclosure. (See reference...) Figure 6 and Figure 7 The apparatus 200 for manufacturing a secondary battery 100 may include: a guide block for fixing the housing of the secondary battery 100; a pressing block for pressing the housing from the opposite side of the guide block; and a roller for rotating and folding the top sealing portion 120b located on the upper surface of the housing.

[0077] The guide block may include: a first guide block 201 that supports at least a portion of the bottom surface of the housing in a first direction D1; and a second guide block 203 that supports at least a portion of the side surface of the housing in a direction opposite to the second direction D2. The push block may include: a first push block 202 that presses the upper portion of the housing on the opposite side of the first guide block 201 in a direction opposite to the first direction D1 to bend the top sealing portion 120b; and a second push block 204 that presses the side portion of the housing, such as the side surface, on the opposite side of the second guide block 203 in the second direction D2 to fold the side sealing portion 120a onto the side surface of the housing.

[0078] The width of the first pressing block 202 in the second direction D2 may be narrower than the width of the top sealing portion 120b in the second direction D2. This is because the side sealing portion 120a, which is folded along the first folding region 121 in the third direction D3, may be damaged in the third direction D3 by the pressing force transmitted in the pressing direction 202', rather than being folded. In some embodiments, the pressing direction 202' may be configured to allow the top sealing portion 120b to bend not only in the direction opposite to the first direction D1, but also partially fold in the third direction D3. That is, the top sealing portion 120b can be bent. In some embodiments, the portion that directly transmits the pressing force may be formed from the center of the top sealing portion 120b in the second direction D2 and in the direction opposite to the second direction D2, and may be spaced apart from the side sealing portions 120a located on both sides by a predetermined distance.

[0079] The rollers may include a first roller 211 and a second roller 212, which can each rotate from opposite ends of the top sealing portion 120b to its central region to fold the top sealing portion 120b. Specifically, because the corner sealing portion 120c folds toward the upper surface of the housing, the corner sealing portion 120c on the left side (as depicted) can be folded by the first roller 211 in a direction opposite to the second direction D2. The corner sealing portion 120c on the right side (as depicted) can be folded by the second roller 212 in the second direction D2. That is, the first roller 211 and the second roller 212 can rotate to reach the upper space of the housing and press the sealing portion to fold it toward the housing.

[0080] In a specific example, the roller can press the upper end of the top sealing portion 120b by approximately 1.3 mm to 1.7 mm, or approximately 70% to 80% of the height of the upper end of the top sealing portion 120b, while moving. In this example, the height of the top sealing portion 120b can be 1.5 mm to 2.7 mm, and the gap between the main body portion 110 and the electrode assembly 20 housed inside the main body portion 110 can be at least 0.6 mm. This configuration is based on the thickness of the sealing portion. When the roller presses the top sealing portion 120b of the sealing portion a distance corresponding to its height, the electrode assembly 20 inside the housing may be damaged due to deformation of the housing. Therefore, the roller can press the upper end of the top sealing portion 120b by a distance shorter than the height of the top sealing portion 120b.

[0081] Figure 8 This is a flowchart of a process for manufacturing a secondary battery 100 according to an embodiment of the present disclosure. (See also...) Figure 8A method for manufacturing a secondary battery 100 may include: in S10, folding a side sealing portion 120a, which extends from the side surface of the housing in a second direction D2 and in a direction opposite to the second direction D2, in a third direction D3 toward the housing. The method further includes: in S20, applying pressure to a top sealing portion 120b, which extends from the upper surface of the housing in the first direction D1, in a direction opposite to the first direction D1. The direction in which the top sealing portion 120b is pressed may be a slightly inclined direction from the direction opposite to the first direction D1 toward the third direction D3. Then, in S30, a roller may rotate in the second direction D2 and in a direction opposite to the second direction D2. As a result, the top sealing portion 120b and the lead terminal piece 111 may be folded for the first time in the third direction D3 by the rotational movement of the roller. Then, in S40, the lead terminal piece 111, which has already been folded once in the third direction D3 while the top sealing portion 120b is being folded, may be folded a second time in a direction opposite to the third direction D3.

[0082] In S50, the inner folded surface of the lead connector 111, which has been folded twice, and the FPCB 130 can be electrically connected to each other. That is, one side of the FPCB 130 can contact the lead connector 111, and the other side can contact the top sealing portion 120b or the upper surface of the housing. Therefore, the insulator can be placed on the other side. In S60, the FPCB 130, which is electrically connected to the lead connector 111, can be connected to the PCM 140.

[0083] Figure 9 A folded side sealing portion 120a is shown according to an embodiment of the present disclosure. (See reference...) Figure 6 and Figure 9 The side sealing portions 120a arranged on their respective sides of the main body portion 110 can be folded in the third direction D3 by the second guide block 203 and the second push block 204. Each side sealing portion 120a can be folded in the third direction D3 such that they contact the main body portion 110 or are positioned adjacent to the main body portion 110. Through this folding, the corner sealing portions 120c can face each other.

[0084] Figure 10 This illustrates how the top sealing portion 120b, according to an embodiment of the present disclosure, is pressed by the first push block 202. (See also...) Figure 6 and Figure 10The top sealing portion 120b can be pressed by the first pressing block 202 in a pressing direction 202' including at least the third direction D3. When the top sealing portion 120b is pressed by the first pressing block 202, the center of the top sealing portion 120b can be bent and slightly tilted in the third direction D3. As the top sealing portion 120b bends, it can fold in the third direction D3 when the roller enters.

[0085] Figure 11 The diagram shows a folded portion F, folded by the first roller 211 and the second roller 212, according to an embodiment of the present disclosure. (See reference...) Figure 6 and Figure 11 The already bent corner sealing portion 120c and top sealing portion 120b can be pressed by the rotational movement of the first roller 211 and the second roller 212, so that not only can the top sealing portion 120b be folded in the third direction D3, but the corner sealing portion 120c can also be folded in the second direction D2 and in the direction opposite to the second direction D2. (Reference) Figure 5 and Figure 11 Each corner sealing portion 120c can be folded along the second folding region 122, the fourth folding region 124, and the fifth folding region 125 to fold in the first direction D1. Corner sealing portions 120c that have already folded in the second direction D2 and the direction opposite to it can be folded along the fourth folding region 124 so that they can be positioned on the top sealing portion 120b that has already folded in the third direction D3. That is, the corner sealing portions 120c can be folded along the fourth folding region 124 so that they overlap with the top sealing portion 120b in the first direction D1.

[0086] Figure 12 An FPCB 130 connected to lead patch 111 is shown according to an embodiment of the present disclosure. Reference Figure 12 When the top sealing portion 120b is folded in the third direction D3, each of the first lead terminal piece 111-1 and the second lead terminal piece 111-2 can also be folded in the third direction D3. While connecting and placing the FPCB 130, the first lead terminal piece 111-1 and the second lead terminal piece 111-2, already folded in the third direction D3, can be folded in the opposite direction to D3. During the second folding of the first lead terminal piece 111-1 and the second lead terminal piece 111-2, the folded inner surfaces of the FPCB 130 and the lead terminal piece 111 can be electrically connected to each other.

[0087] Figure 13 This illustrates how a folded portion F is formed when the top sealing portion 120b and the side sealing portion 120a are folded in a first direction D1, according to an embodiment of the present disclosure. Figure 14 A fold portion F is shown according to an embodiment of the present disclosure, comprising a first fold portion F1, a second fold portion F2, and a third fold portion F3. (See reference...) Figure 13 and Figure 14 The top sealing portion 120b and side sealing portion 120a of the folded portion F can be folded in the third direction D3, and the corner sealing portion 120c of the folded portion F at the boundary between the top sealing portion 120b and the side sealing portion 120a can be folded along multiple folding regions. Through the multiple folding regions, the folded portion F can form multiple layers stacked in the first direction D1. (Reference) Figure 14 The folded portion F may include a first folded portion F1 at the top, a second folded portion F2 in the middle, and a third folded portion F3 at the bottom.

[0088] The first fold portion F1 may be part of the corner sealing portion 120c (which is one of the two regions of the corner sealing portion 120c divided by the fifth fold region 125) and the region adjacent to the side sealing portion 120a. The second fold portion F2 may be the other region of the two regions of the corner sealing portion 120c divided by the fifth fold region 125 and the region adjacent to the top sealing portion 120b, and the second fold portion F2 may be folded under the first fold portion F1. The third fold portion F3 may be placed below the first fold portion F1 and the second fold portion F2, and may be part of the top sealing portion 120b. Therefore, in this example, the fold portions F are formed by stacking three layers.

[0089] The corner sealing portion 120c can be folded to be adjacent to the upper surface of the housing. The folding area may include a first folding area 121, a second folding area 122, and a third folding area 123. The side sealing portion 120a folds along the first folding area 121 in a third direction D3. The second folding area 122 extends from the first folding area 121. The top sealing portion 120b folds along the third folding area 123 in a first direction D1. The folding area may also include a fourth folding area 124 and a fifth folding area 125. The corner sealing portion 120c folds along the fourth folding area 124 in a second direction D2 and in a direction opposite to the second direction D2. When the corner sealing portion 120c folds along the second folding area 122, it folds within the corner sealing portion 120c along the fifth folding area 125.

[0090] Figure 15 This illustrates how a conventional FPCB 130' extends relative to a secondary battery. Figure 16 This illustrates how an FPCB 130 extends relative to a secondary battery according to one embodiment of the present disclosure. Reference Figure 15The FPCB 130' extends along its path around the sealing portion, thereby increasing the overall length or width of the battery pack, including the secondary battery. With this increased length or width, the battery pack capacity can be increased, for example, by more than nine percent, depending on the design. This configuration may result in a decrease in energy density. However, as... Figure 16 As shown, when the sealing portion is folded to allow the FPCB 130 to extend from the lead tab 111 and along the housing, the space occupied by the FPCB 130 along its extension path is reduced compared to the conventional example, thereby increasing the energy density.

[0091] Although the present disclosure has been described above with reference to embodiments thereof, the present disclosure is not limited thereto. Various modifications and variations can be made to it within the spirit of the present disclosure by those skilled in the art.

Claims

1. A secondary battery, comprising: Electrode assembly; as well as The housing includes: The main body, in which the electrode assembly is housed; A cover that covers the opening of the main body. The sealing portion is formed at the contact point between the outer surface of the main body and the outer surface of the cover, thereby sealing the electrode assembly within the housing. The sealing portion includes: The top sealing portion extends from the upper surface of the housing in a first direction; A plurality of side sealing portions, each of the plurality of side sealing portions extending from a side surface of the housing in a second direction intersecting the first direction or in a direction opposite to the second direction; and The corner sealing portion folds in the first direction when the top sealing portion and the plurality of side sealing portions fold upward at a third direction intersecting the first direction and the second direction.

2. The secondary battery according to claim 1, wherein, The corner sealing portion is folded in the direction opposite to the second direction.

3. The secondary battery according to claim 1, wherein, The corner sealing portion is on the top sealing portion.

4. The secondary battery according to claim 2, wherein, The top sealing portion and the plurality of side sealing portions are folded upwards along the plurality of folding regions on the third party, and The plurality of folded areas include a first folded area, a second folded area, and a third folded area. The plurality of side sealing portions are folded upward along the first folded area on the third folded area. The second folded area extends from the first folded area. The top sealing portion is folded upward along the third folded area on the third folded area.

5. The secondary battery according to claim 4, wherein, The corner sealing portion includes multiple corner sealing portions, and the multiple folded areas further include: The fourth fold region, wherein the plurality of corner sealing portions, after having been folded upward along the second fold region in the third direction, are folded along the fourth fold region in the second direction or in the direction opposite to the second direction; and The fifth folding region is formed within the plurality of corner sealing portions when each of the plurality of corner sealing portions is folded along the fourth folding region.

6. The secondary battery according to claim 5, wherein, The fourth folded region is located above the third folded region in the first direction.

7. The secondary battery according to claim 6, wherein, The fifth fold region extends from the upper edge of the sealing portion to the second fold region.

8. The secondary battery of claim 6, wherein each of the plurality of corner sealing portions is folded in the first direction by folding along the fourth fold region and the fifth fold region.

9. The secondary battery according to claim 1, wherein, First lead terminals connected to a plurality of first electrode terminals of the electrode assembly and second lead terminals connected to a plurality of second electrode terminals of the electrode assembly extend in the first direction, and When the top sealing portion folds upward on the third party, each of the first lead terminal and the second lead terminal also folds upward on the third party, and then folds in the opposite direction to the third party.

10. The secondary battery according to claim 9, wherein, The first lead terminal and the second lead terminal are electrically connected to a flexible printed circuit board, and the flexible printed circuit board extends in the second direction.

11. An apparatus for manufacturing a secondary battery, the apparatus comprising: A guide block that secures the housing of the secondary battery, the housing including a main body portion for receiving an electrode assembly, a cover covering an opening in the main body portion to seal the electrode assembly, and a sealing portion in which the outer surfaces of the main body portion and the outer surfaces of the cover contact each other to seal the electrode assembly in the housing; A push block, configured to apply pressure to the housing on a side opposite to the guide block; as well as A roller configured to rotate on and fold the top sealing portion located on the upper surface of the housing.

12. The apparatus according to claim 11, wherein, The boot block includes: A first guide block supports at least a portion of the lower surface of the housing in a first direction; and The second guide block supports at least a portion of the side surface of the housing in a direction opposite to the second direction, and The pushing block includes: A first pressing block is configured to press the upper portion of the housing in a direction opposite to the first direction on a side opposite to the first guide block, thereby bending the top sealing portion; and The second push block is configured to press a side portion of the housing in the second direction on the side opposite to the second guide block to fold each of the plurality of side sealing portions on the respective side surface of the housing.

13. The apparatus according to claim 12, wherein, The width of the first pressing block in the second direction is smaller than the width of the top sealing portion in the second direction.

14. The apparatus according to claim 12, wherein, The rollers include a first roller and a second roller, which rotate from opposite ends of the top sealing portion to the central region of the top sealing portion to fold the top sealing portion.

15. A method of manufacturing a secondary battery, the secondary battery comprising an electrode assembly and a housing, the housing comprising: The method comprises: a main body portion accommodating the electrode assembly, a cover covering an opening of the main body portion, wherein a sealing portion is formed at the contact point between the outer surface of the main body portion and the outer surface of the cover, thereby sealing the electrode assembly within the housing; the sealing portion comprising a top sealing portion extending from the upper surface of the housing in a first direction and a plurality of side sealing portions each extending from the side surface of the housing in a second direction intersecting the first direction or in a direction opposite to the second direction; the method further comprises: Each of the plurality of side sealing portions is folded upward toward the housing on a third side intersecting the second direction; Pressure is applied to the top sealing portion of the sealing portion in a direction opposite to the first direction; and The top sealing portion is folded upward by the rotational movement of multiple rollers on the third party, so as to fold the corner sealing portion of the sealing portion in the second direction and the direction opposite to the second direction.

16. The method according to claim 15, wherein, The secondary battery further includes: a first lead terminal connected to a plurality of first electrode terminals of the electrode assembly and extending in the first direction; and a second lead terminal connected to a plurality of second electrode terminals of the electrode assembly and extending in the first direction. Wherein, the corner sealing portion of folding the sealing portion in the second direction and the direction opposite to the second direction includes: when the top sealing portion is folded upward in the third direction, folding each of the first lead terminal piece and the second lead terminal piece upward in the third direction, and The method further includes: Fold the already folded first lead connector and second lead connector in the opposite direction to the third party; and After folding the first lead connector and the second lead connector, the first lead connector and the second lead connector are electrically connected to a flexible printed circuit board extending in the second direction.

17. The method according to claim 16, wherein, The flexible printed circuit board extends from the first lead tab and the second lead tab along the upper surface of the housing.

18. The method according to claim 15, wherein, While moving, the plurality of rollers press the upper end of the top sealing portion by 1.3 mm to 1.7 mm or a distance corresponding to 70% to 80% of the height of the upper end of the top sealing portion.

19. The method according to claim 15, wherein, The corner sealing portion is folded to be adjacent to the upper surface of the housing.

20. The method according to claim 19, wherein, The top sealing portion and the side sealing portion are folded upwards along multiple folding areas on the third side. The plurality of folded areas include a first folded area, a second folded area, and a third folded area. The plurality of side sealing portions fold upwards along the first folded area at the third folded area. The second folded area extends from the first folded area. The top sealing portion folds upwards along the third folded area at the third folded area. The plurality of folded regions further include: The fourth fold region, each of the plurality of corner sealing portions, after having already folded upward along the second fold region along the third party, folds along the fourth fold region in the second direction or in the direction opposite to the second direction; and The fifth folding region is formed within the plurality of corner sealing portions when each of the plurality of corner sealing portions is folded along the fourth folding region.

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