Sensor assembly, battery assembly including this and method for manufacturing a battery assembly

Abstract

A battery assembly (400) comprises a battery cell stack (410) having a plurality of battery cells extending in a first direction and arranged transversely to the first direction in a second direction, a side end plate (500) arranged on one side of the battery cell stack (410) in the second direction, and a sensor assembly (600) covering a region of a side face of the battery cell stack (410) in the first direction. The sensor assembly (600) comprises a sensor board and a sensor support frame (700) that supports the sensor board.

Description

TECHNICAL AREA

[0001] The present disclosure relates to a sensor assembly, a battery assembly comprising this sensor assembly, and a method for manufacturing the battery assembly. BACKGROUND

[0002] Electric vehicles are environmentally friendly and can help to mitigate environmental problems and the depletion of petroleum resources. Electric vehicles include, for example, plug-in hybrid vehicles (PHEVs), battery electric vehicles (BEVs), and fuel cell electric vehicles (FCEVs).

[0003] In some cases, an electric vehicle may have a battery housing that contains battery cells. An electric vehicle can use battery cells as energy sources, and a cell-to-pack (CTP) battery assembly (e.g., cells directly integrated into the battery pack) may be provided inside the battery housing to increase the capacity of the battery cells contained within the battery pack.

[0004] In some cases, the battery assembly may include a sensor assembly. The sensor assembly can be manually connected to the battery pack. BRIEF EXPLANATION

[0005] The present disclosure describes a sensor assembly that can be automated in a manufacturing process and a battery assembly that incorporates this.

[0006] According to one aspect of the subject matter described in this application, a battery assembly comprises a battery cell stack having a plurality of battery cells extending in a first direction and arranged transversely to the first direction in a second direction, a side end plate arranged on one side of the battery cell stack and facing the plurality of battery cells in the second direction, and a sensor assembly (hereinafter referred to as: sensor assembly) covering or overlapping a region of a side face of the battery cell stack and facing the plurality of battery cells in the first direction, wherein the sensor assembly comprises a sensor board and a sensor support frame supporting the sensor board. The sensor support frame comprises a board support element supporting the sensor board and extending from the side of the battery cell stack in the second direction, a side support element (e.g., a web or...)beam), which extends from one end of the circuit board support in the first direction and is supported by the side end plate, and a guide projection which extends from the end of the circuit board support in the second direction and is located on the side end plate.

[0007] Embodiments according to this aspect may have one or more of the following features. For example, the guide projection may have a first stop region extending in the first direction and a second stop region extending from the first stop region in a third direction transverse to the first and second directions. In some examples, the first stop region and the second stop region may contact the side end plate. In some examples, the side end plate may have a first contact surface facing a side of the first stop region in the first direction and contacting an end of the first stop region, and a second contact surface facing a side of the second stop region in the third direction and contacting an end of the second stop region.

[0008] For example, in some embodiments the side end plate can define a recessed area between the first contact surface and the second contact surface, wherein the recessed area is recessed in a direction away from the guide projection.

[0009] For example, in some embodiments, the sensor assembly may further include a busbar (e.g., current busbar or busbar) that is electrically connected to the plurality of battery cells, wherein the sensor support frame has a plurality of busbar support members that support the busbar and extend from the circuit board support member in a third direction transverse to the first and second directions. The plurality of busbar support members may be spaced apart from each other in the second direction to define a plurality of tab slots extending in the third direction. In some examples, each of the plurality of busbar support members may have a projection arranged at one end of the busbar support members in the third direction, projecting in the first direction and supporting the busbar.

[0010] For example, in some embodiments, the side end plate can define a seating groove that is recessed in the second direction and receives the side support member. For example, the seating groove can have a first seating area extending in the first direction, a second seating area extending from a first end of the first seating area in a third direction transverse to the first and second directions, a third seating area extending from a second end of the first seating area in the third direction, and a fourth seating area extending from the third seating area in the first direction.

[0011] For example, in some examples the side support part may have a first side area extending in the first direction and inserted into the first seating area, a second side area extending from a first end of the first side area in the third direction and inserted into the second seating area, a third side area extending from a second end of the first side area in the third direction and inserted into the third seating area, and a fourth side area extending from the third side area in the first direction and inserted into the fourth seating area.

[0012] For example, in some embodiments, the side end plate has an edge cover arranged on one side of the first seating area in the third direction, which supports the side support member. In some examples, the side end plate further has a fastening device projecting from the edge cover toward the first seating area and arranged between the second and third seating areas, the fastening device being configured to secure the side support member. In some embodiments, the seating groove extends in the first direction, and the side support member extends in the first direction and is inserted into the seating groove.

[0013] For example, in some embodiments the sensor assembly may further include a conductor which is electrically connected to the sensor board, wherein the conductor is arranged on a surface of the side support and extends along the side support in the first direction.

[0014] According to another aspect, a sensor assembly comprises a sensor board, a busbar, and a sensor support frame that supports the busbar and the sensor board. The sensor support frame has a side support extending in a first direction, a board support extending from the side support in a second direction transverse to the first direction, with the sensor board attached to the board support, and a plurality of busbar support members to which the busbar is attached. The plurality of busbar support members extends from the board support in a third direction transverse to the first and second directions and is spaced apart from each other in the second direction.

[0015] Embodiments according to this aspect may have one or more of the following features. For example, the sensor support frame further has a guide projection extending from the circuit board support to an outer surface of the sensor support frame in the second direction, wherein the guide projection has a first stop area extending in the first direction and a second stop area extending from the first stop area in the third direction.

[0016] Embodiments according to this aspect may have one or more of the following features. For example, the side support part has a first side region extending in the first direction, a second side region extending from a first end of the first side region in the third direction, a third side region extending from a second end of the first side region in the third direction, and a fourth side region extending from the third side region in the first direction.

[0017] In some examples, each of the plurality of busbar support members has a projection located at one end of the busbar support members in the third direction, projecting in the first direction and supporting the busbar. In some examples, the sensor assembly further includes a conductor electrically connected to the sensor board, the conductor being located on a surface of the side support member and extending along the side support member in the first direction.

[0018] According to another aspect, a method for manufacturing a battery assembly comprises: stacking a plurality of battery cells extending in a first direction, wherein the plurality of battery cells are stacked in a second direction transverse to the first direction, arranging a pair of side end plates on opposite sides of the plurality of battery cells, wherein the pair of side end plates faces the plurality of battery cells in the second direction, and assembling a sensor assembly and the pair of side end plates in a third direction transverse to the first and second directions. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and other objects, features and advantages of the present disclosure will become clearer from the following detailed description in conjunction with the accompanying drawings. Fig. Figure 1 is a perspective view showing an example of a battery pack. Fig. Figure 2 is a perspective exploded view of the battery pack. Fig. Figure 3 is a perspective view showing an example of a battery assembly. Fig. Figure 4 is a perspective exploded view of the battery assembly. Fig. Figure 5 is a perspective view showing an example of a sensor assembly. Fig. Figure 6 is a perspective view of the sensor assembly from a different angle. Fig. 7 is an enlarged view of the in Fig. 3 shown in section A. Fig. Figure 8 is a perspective view showing an example of a sensor assembly. Fig. Figure 9 is a perspective view before the sensor assembly is mounted on a stack of battery cells. Fig. Figure 10 is a view showing an example of a battery cell inserted into a tab slot of a busbar support part. Fig. Figures 11 to 13 show exemplary processes in which a sensor assembly is moved in a third direction to the opposite side and mounted on a battery cell stack. Fig. Figure 14 is a flowchart showing an example of a process for manufacturing a battery assembly. DETAILED DESCRIPTION

[0020] One or more embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. When reference numerals are added to the components in the drawings, it is noted that the same components are designated by the same reference numerals even if they are shown in different drawings. Furthermore, a detailed description of the embodiments of the present disclosure is omitted where it is determined that a detailed description of the associated known configurations and functions may hinder the understanding of the embodiments of the present disclosure.

[0021] Below, one or more embodiments of the present disclosure are described with reference to the Fig. Items 1 to 14 are described in detail.

[0022] Fig. Figure 1 is a perspective view of a battery pack. Fig. Figure 2 is a perspective exploded view of a battery pack.

[0023] With reference to Fig. 1 and Fig. Figure 2 shows that a battery pack 100 can have a battery housing 200 and a pack cover 300 coupled to the battery housing 200.

[0024] The battery housing 200 can define a space that accommodates a battery assembly 400. For example, the battery housing 200 can have a base plate 250, as well as a front element 210 and a rear element 220, which are coupled to the base plate 250.

[0025] In some embodiments, the battery housing 200 may have a pair of side elements 230 that connect the front element 210 and the rear element 220 and extend parallel to each other. The front element 210, the rear element 220, and the pair of side elements 230 may be coupled to the base plate 250 to define a space in which the battery assembly 400 is accommodated.

[0026] The battery assembly 400 can be mounted on the battery housing 200 in a cell-to-pack (CTP) configuration. Since the battery assembly 400 can, in some cases, be mounted on the battery housing 200 without the battery module housing, the battery capacity of the battery pack 100 can be relatively large.

[0027] To enable the battery assemblies 400 to be arranged parallel to one another within the interior of the battery housing 200, the battery housing 200 can have a transverse element 240 for guiding one position of the battery assembly 400. The transverse element 240 can extend to connect a pair of side elements 230 between the front element 210 and the rear element 220. The transverse element 240 can be fastened to the base plate 250 by a fastening element 260.

[0028] Fig. Figure 3 is a perspective view of a battery assembly. Fig. Figure 4 is a perspective exploded view of a battery assembly. Fig. Figure 5 is a perspective view of a sensor assembly. Fig. Figure 6 is a perspective view of a sensor assembly, viewed from a different angle. Fig. 7 is an enlarged view of the in Fig. 3 shown in section A.

[0029] With reference to Fig. 3 to 7, the battery assembly 400 can have a battery cell stack 410 comprising a plurality of battery cells 420 extending in a first direction (the X direction or a direction opposite to the X direction) and arranged in a second direction (the Y direction or a direction opposite to the Y direction) perpendicular to the first direction.

[0030] The battery assembly 400 can include side end plates 500 arranged on opposite sides of the battery cell stack 410 in the second direction, and sensor assemblies 600 arranged on opposite sides of the battery cell stack 410 in the first direction.

[0031] The battery cell stack 410 can have a surface pressure element 430 located between the battery cells 420 and a cooling plate that contacts the battery cells 420 to cool them. An insulating plate 540 can be attached to the side end plate 500.

[0032] A sensor assembly 600 can include a sensor board 610 for measuring a voltage of the battery cells 420, a line 620 that is electrically connected to the sensor board 610, a busbar 630 that is electrically connected to the battery cell 420, and a temperature sensor 640 for measuring a temperature of the battery cells 420.

[0033] The sensor assembly 600 can include a sensor support frame 700, which supports the sensor board 610, the cable 620, the busbar 630, and the temperature sensor 640. The sensor support frame 700 can extend along one circumference of the battery cell stack 410 and can cover opposite areas of the battery cell stack 410 in the first direction. That is, the sensor board 610, the cable 620, the busbar 630, and the temperature sensor 640 can be attached to the sensor support frame 700.

[0034] The sensor support frame 700 can have a circuit board support part 710, to which the sensor circuit board 610 is attached and which supports the sensor circuit board 610, a side support part 720, to which the line 620 and the temperature sensor 640 are attached, and a busbar support part 730, which supports the busbar 630.

[0035] A pair of circuit board support elements 710 may be provided and may be located on one side (in the X direction) of the battery cell stack 410 in the first direction or on an opposite side (opposite to the X direction) thereof in the first direction. The pair of circuit board support elements 710 may extend in the second direction from opposite sides of the battery cell stack 410 in the first direction. Insulation covers 440 may be provided on opposite sides of the circuit board support element 710 in the first direction.

[0036] A pair of side support parts 720 is provided, and the pair of circuit board support parts 710 can extend on an opposite side in the first direction to the pair of circuit board support parts 710, wherein the circuit board support part 710 is provided on one side (of the X direction) of the battery cell stack 410 in the first direction to the circuit board support part 710, which is provided on an opposite side of it in the first direction (a direction opposite to the X direction).

[0037] Cables 620 can be attached to a pair of surfaces of the side support 720 that face opposite sides in the first direction. The cable 620 can be electrically connected not only to the sensor board 610 but also to the temperature sensor 640. To allow for the attachment of the cables 620, the side support 720 can be made of a material that can be manufactured as an injection-molded product.

[0038] The pair of side support parts 720 can be supported by the side end plates 500, which are provided on opposite sides of the battery cell stack 410 in the second direction. The side support parts 720 can be arranged in a region on one side (the Z-direction) in the third direction on opposite sides of the battery cell stack 410 in the second direction.

[0039] The busbar support 730 can extend from the circuit board support 710 to an opposite side (a direction opposite to the Z-direction) in the third direction. One end 731 of the busbar support 730, facing an opposite side in the third direction, can project to one side (the X-direction) in the first direction, so that the busbar 630 is supported between one end 731 and the circuit board support 710.

[0040] A plurality of busbar support elements 730 can be arranged to be spaced apart from each other in the second direction. Between the plurality of busbar support elements 730, tab slots 732 can be formed, which have a shape that is open to an opposite side in the third direction.

[0041] The lug slots 732 can extend in the third direction between the majority of the busbar support members 730. The lug slots 732 can be spaces through which electrode lugs 421 (see Fig. 11) of the battery cells 420. The electrode tabs 421 of the battery cells 420 can pass through the tab slots 732 to be electrically connected to the busbar 630.

[0042] The structure allows the sensor assembly 600 to be moved from an area on one side (the Z-direction) of the battery cell stack 410 in the third direction towards the battery cell stack 410, thereby facilitating the automation of the manufacturing process of the battery assembly 400.

[0043] In some embodiments, a position of the sensor assembly 600 can be fixed if the sensor assembly 600 is moved in the direction of the battery cell stack 410 to an opposite side in the third direction (a direction opposite to the Z direction).

[0044] In some examples, the sensor support frame 700 can have guide projections 740 that interlock with the side end plates 500. The guide projections 740 can extend outwards from the circuit board support part 710 to an outer side in the second direction and sit on the side end plates 500. The outer side in the second direction can be opposite sides in the second direction.

[0045] The guide projection 740 can be arranged in a region of the side support element 720 on an opposite side in the third direction. The guide projection 740 can have a first stop area 741 extending in the first direction and a second stop area 742 extending from one end of the first stop area 741 in the first direction to an opposite side (in a direction opposite to the Z-direction) in the third direction.

[0046] Both the first stop area 741 and the second stop area 742 can contact the side end plate 500. More precisely, the side end plate 500 can have a first contact surface 551 facing a side in the first direction to contact an end of the first stop area 741, and a second contact surface 552 facing a side in the third direction to contact an end of the second stop area 742.

[0047] The second contact surface 552 can extend from the first contact surface 551 to one side in the first direction. A region where the first contact surface 551 and the second contact surface 552 face each other can have a shape that is recessed in the direction in which they are spaced from the guide projection 740. In other words, the region where the first contact surface 551 and the second contact surface 552 face each other can be shaped to be open on one side in the first direction and on one side in the third direction.

[0048] The structure guides the position of the sensor assembly 600 even when it is moved from one area of ​​the battery cell stack 410 to one side in the third direction to an opposite side in the third direction, thus improving the manufacturing performance of the battery assembly 400.

[0049] In some examples, the side support part 720 can be supported by the side end plate 500 when the sensor assembly 600 is mounted on the battery assembly 400, so that one position of it is fixed.

[0050] In some embodiments, the side end plate 500 may have a seat groove 520 which is concave on an outside in the second direction to define a space into which the side support part 720 is inserted.

[0051] The seat groove 520 can have a first seating area 521 extending in the first direction, a second seating area 522 extending from one end of the first seating area 521 to one side (the Z-direction) in the third direction, a third seating area 523 extending from an opposite end of the first seating area 521 to one side (the Z-direction) in the third direction, and a fourth seating area 524 extending from the third seating area 523 to one side (the X-direction) in the first direction. The first to fourth seating areas 521, 522, 523, and 524 can be provided in multiples, and the fourth seating area 524 can be provided on an opposite side (in a direction opposite to the X-direction) of the second seating area 522 in the first direction.

[0052] The side support part 720 can have a first side area 721 extending in the first direction to be inserted into the first seating area 521, a second side area 722 extending from one end of the first side area 721 to a side (the Z-direction) in the third direction to be inserted into the second seating area 522, a third side area 723 extending from an opposite end of the first side area 721 to a side (the Z-direction) in the third direction to be inserted into the third seating area 523, and a fourth side area 724 extending from the third side area 723 to a side (the X-direction) in the first direction to be inserted into the fourth seating area 524.The first to fourth side areas 721, 722, 723 and 724 can be provided in a plurality, and the fourth side area 724 can be provided on an opposite side (in a direction opposite to the X direction) of the second side area 522 in the first direction.

[0053] The side end plate 500 can have an edge cover 510 which is formed on one side (in the Z direction) of the seat groove 520 in the third direction and carries the side support part 720, as well as a fastening device 530 which projects from the edge cover 510 on an opposite side (in a direction opposite to the Z direction) in the third direction.

[0054] The edge cover 510 can extend in the first direction and can contact an end of the side support 720 that faces one side (the Z-direction) in the third direction. The fastening device 530 can project from the edge cover 510 toward the first seating area 521 between the second seating area 522 and the third seating area 523. The fastening device 530 can fix the positions of the first to third side areas 721, 722, and 723 in order to fix the position of the side support 720.

[0055] Fig. Figure 8 is a perspective view showing an example of a sensor assembly.

[0056] Referring to Fig. 8 the side support part 720 of Fig. 8 in contrast to the one in Fig. The sensor assembly 600 shown in Figure 7 has a shape that extends in the first direction.

[0057] In some embodiments, the side end plate 500 can have a shape in which a seat groove 520 extends in a first direction, in contrast to the one shown in Fig. 7 shown side end plate 500.

[0058] The following describes a method for manufacturing the battery assembly 400 with reference to the Fig. 9 to 14 are described in detail.

[0059] Fig. Figure 9 is a perspective view before a sensor assembly is mounted on a stack of battery cells. Fig. Figure 10 shows a view in which a battery cell is inserted into a tab slot of a busbar support component. Fig. Figures 11 to 13 are views showing a process in which a sensor assembly is moved in a third direction to an opposite side and mounted on a battery cell stack. Fig. Figure 14 is a flowchart showing a process for manufacturing a battery assembly.

[0060] With reference to the Fig. 9 to 14 a process for manufacturing the battery assembly 400 (see Fig. 3) include a cell stacking operation S10, a plate stacking operation S20 and a sensor assembly assembly operation S30.

[0061] The cell stacking process S10 can be a process of stacking the battery cells 420 (see Fig. 4) extend in the first direction (the X direction or a direction opposite to the X direction) and in the second direction (the Y direction or a direction opposite to the Y direction), which is perpendicular to the first direction.

[0062] When the battery cells 420 are stacked in the cell stacking process S10, the surface pressure elements 430 and the cooling plates can be stacked together between the battery cells 420.

[0063] The plate stacking process S20 can be a process in which the side end plates 500 are arranged on opposite sides of the battery cell 420 in the second direction after the cell stacking process S10.

[0064] The in Fig. The battery cell stack 410 shown can be in a state in which a cell stacking operation S10 and a plate stacking operation S20 have been carried out.

[0065] The sensor assembly assembly operation S30 of the sensor assembly can be an operation in which the sensor assembly 600 and the side end plate 500 are assembled by assembling the sensor assembly 600 in the third direction of the battery cell 420 after the plate stacking operation S20.

[0066] In the sensor assembly process S30, the sensor assembly 600, which is mounted in the side end plate 500, can be in a state in which the sensor board 610, the line 620, the busbar 630 and the temperature sensor 640 are attached to the sensor support frame 700.

[0067] The sensor assembly 600, to which the sensor board 610, the line 620, the busbar 630 and the temperature sensor 640 are attached, can be moved in the third direction towards an opposite side (a direction opposite to the Z-direction) to a circumferential area (e.g. edge area) of the battery cell stack 410, specifically to an area on one side of the battery cell stack 410 in the third direction.

[0068] When the sensor assembly 600 is moved to an opposite side (a direction opposite to the Z-direction) in the third direction, the electrode tab 421 of the battery cell 420 can be inserted along a tab slot 732 provided between the busbar support parts 730.

[0069] The electrode tabs 421 of the pair of adjacent battery cells 420 can be connected to each other on opposite sides in the first direction. In addition, the connected electrode tabs 421 can overlap on their surfaces facing opposite sides in the first direction.

[0070] To simplify the manufacturing process, the tab slot 732 can be moved in the third direction, so that an area extending in the first direction is included in addition to an area where the electrode tabs 421 are connected to each other. If the tab slot 732 has a shape extending along the third direction, the manufacturing process can be correspondingly simplified when the sensor assembly 600 is mounted on the battery cell stack 410 as a single assembly.

[0071] As described above, if the tab slot 732 is moved along the electrode tab 421 to an opposite side (one direction opposite to the Z-direction) in the third direction, the guide projection 740 can engage in the side end plate 500 and the side support part 720 can simultaneously be inserted into the seat groove 520, as shown in Fig. 7 shown.

[0072] In some embodiments, a separate manufacturing process can be omitted, since a separate busbar or conductor configuration in the sensor assembly 600 is not required. Furthermore, since the manufacturing of the battery assembly 400 is completed as soon as the sensor assembly 600 is moved in the third direction and inserted into the side end plate 500, the manufacturing process of the battery assembly 400, which is located in the battery pack 100 (see Fig. 1) is housed in the form of a CTP, simplifying and thus improving productivity.

[0073] According to the present technology, the sensor assembly can be mounted on the battery assembly while the cable is attached to the sensor assembly, thus enabling the manufacturing process of the sensor assembly and the battery assembly containing it to be automated, thereby improving productivity.

[0074] Furthermore, according to the present disclosure, during the assembly of the sensor assembly, the position of the sensor assembly is guided by the side end plate, so that the manufacturing process of the battery assembly can be automated, thereby improving productivity.

[0075] Furthermore, various effects identified directly or indirectly through this document can be specified.

[0076] The above description is a simple, exemplary description of the technical spirit of the present disclosure, and a person skilled in the art to whom the present disclosure applies may make various corrections and modifications without departing from the essential features of the present disclosure.

[0077] Therefore, the embodiments disclosed in the present disclosure do not serve to limit the technical spirit of the present disclosure, but rather to describe it, and the scope of the technical spirit of the present disclosure is not limited by the embodiments. The scope of protection of the present disclosure should be interpreted in accordance with the following claims, and the technical spirit in the corresponding area should be interpreted in such a way as to encompass the scope of protection of the present disclosure. REFERENCE MARK LIST 100 battery pack 200 battery cases 210 front element 220 rear element 230 page elements 240 transverse elements 250 base plate 260 fastening element 300 Pack Cover 400 battery assembly 410 battery cell stacks 420 battery cell 430 Surface printing element 440 Insulation cover 500 side end plate 510 Edge cover 520 Seat groove 521 first seating area 522 second seating area 523 third seating area 524 fourth seating area 530 Mounting device 540 Insulation board 551 first contact surface 552 second contact surface 600 Sensor assembly 610 Sensor board 620 line 630 busbar 640 temperature sensor 700 sensor mounting frames 710 Circuit board support 720 Side support part 721 first page area 722 second page area 723 third page area 724 fourth page area 730 busbar support component 731 one end of the busbar support section 732 flap slots 740 lead 741 first stop area 742 second stop area S10 Cell stacking process S20 plate stacking process S30 sensor assembly process

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