Busbar assembly and battery pack including same

Abstract

A busbar assembly according to one embodiment of the present invention includes: a first busbar and a second busbar arranged parallel to each other, each of the first busbar and the second busbar including a body portion and ends extending from both ends of the body portion and having through holes defined therein; a first insulating layer enclosing the body portion of the first busbar; a second insulating layer enclosing the body portion of the second busbar; and caps enclosing the ends of the first busbar and the second busbar that are adjacent to each other.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0103595, dated August 8, 2023, and all contents disclosed in the documents of this Korean patent application are incorporated herein by reference.

[0002] The present invention relates to a bus bar assembly and a battery pack including the same, and more particularly to a bus bar assembly with improved insulation stability and a battery pack including the same. [Background technology]

[0003] In modern society, the use of portable devices such as mobile phones, laptops, video cameras, and digital cameras has become commonplace, leading to active development of technologies related to these mobile devices. Furthermore, rechargeable secondary batteries are being used as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (P-HEVs), etc., as a solution to address air pollution caused by existing gasoline-powered vehicles that use fossil fuels, and there is an increasing need for development of secondary batteries.

[0004] Currently commercially available secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, and lithium secondary batteries. Of these, lithium secondary batteries are attracting attention due to their advantages of almost no memory effect compared to nickel-based secondary batteries, free charging and discharging, very low self-discharge rate, and high energy density.

[0005] Such lithium secondary batteries mainly use lithium-based oxides and carbon materials as positive and negative electrode active materials, respectively, and include an electrode assembly in which positive and negative electrode plates coated with the positive and negative electrode active materials are disposed with a separator between them, and a battery case that hermetically houses the electrode assembly together with an electrolyte.

[0006] Generally, lithium secondary batteries can be classified into can-type secondary batteries, in which an electrode assembly is housed in a metal can, and pouch-type secondary batteries, in which an electrode assembly is housed in a pouch made of an aluminum laminate sheet, depending on the shape of the exterior material.

[0007] While secondary batteries used in small devices typically have two or three battery cells, secondary batteries used in medium- to large-sized devices such as automobiles typically use a battery module in which multiple battery cells are electrically connected. Such battery modules improve capacity and output by connecting multiple battery cells in series or parallel to form a stack of battery cells. Furthermore, one or more battery modules may be installed with various control and protection systems, such as a battery disconnect unit (BDU), battery management system (BMS), and cooling system, to form a battery pack.

[0008] In a battery pack made up of multiple battery modules, the heat generated from the multiple battery cells can be combined in a small space, causing the temperature to rise rapidly. In other words, a battery module in which multiple battery cells are stacked and a battery pack equipped with such a battery module can produce high output, but if the heat is not properly dissipated from the battery cells or if thermal runaway occurs in the battery cells, there is a high possibility of continuous fires and subsequent explosions.

[0009] Meanwhile, a bus bar connected to the battery module is provided inside the battery pack.

[0010] FIG. 1 is an exploded perspective view and a combined perspective view of a conventional busbar assembly.

[0011] Referring to FIG. 1, a conventional busbar assembly 10 includes a busbar 20, a covering 20C surrounding the busbar 20, a cap CP, and a tape AL for fixing the cap CP. The busbar 20 is a rod-shaped metal member extending longitudinally. Through-holes HH may be formed at both ends of the busbar 20 for connection to terminal busbars of a battery module. The busbar 20 serves as a high voltage (HV) connection in a battery pack. The HV connection refers to a connection that functions as a power source for supplying power. The busbar 20 guides the electrical connection of the battery modules and is generally made of a metal material with excellent electrical conductivity. For example, the busbar 20 may include copper (Cu).

[0012] A covering (20C) can encase the bus bar 20. The covering (20C) can include an electrically insulating material, such as silicone or epoxy. Because the covering (20C) encases the bus bar 20, through which a high current flows, the bus bar 20 is prevented from coming into contact with other electrical components or conductive members other than the terminal bus bar of the battery module, which could cause a short circuit.

[0013] Fasteners can be inserted into the through holes (HH) of the busbar 20 to connect the busbar 20 to the terminal busbars of the battery module. Caps (CP) are attached to both ends of the busbar 20 for insulation. The caps (CP) may be, for example, rubber caps. The caps (CP) can be attached to the covering (20C) using tape (AL).

[0014] However, if a fire breaks out inside the battery pack, the flame temperature will be as high as approximately 1000°C, which may melt the coating (20C) surrounding the busbar 20 or the cap (CP) and tape (AL) and expose the busbar 20. If the exposed busbar 20 comes into contact with other conductive parts and a short circuit occurs, the internal flame may spread further and even propagate to the outside of the battery pack. Ultimately, this may lead to an explosion of the battery pack or the vehicle in which the battery pack is installed.

[0015] Therefore, there is a need for technological development of a bus bar assembly that can maintain electrical insulation even if a flame occurs inside the battery pack. Summary of the Invention [Problem to be solved by the invention]

[0016] An object of the present invention is to provide a bus bar assembly that does not melt and maintains electrical insulation even when a flame occurs inside the battery pack, and a battery pack including the bus bar assembly.

[0017] However, the problems to be solved by the embodiments of the present invention are not limited to the above-mentioned problems, and can be variously expanded within the scope of the technical ideas included in the present invention. [Means for solving the problem]

[0018] The busbar assembly of the present invention includes a first busbar and a second busbar arranged side by side, each of the first busbar and the second busbar including a body portion and end portions extending from both ends of the body portion and having through holes defined therein; a first insulating layer surrounding an outer peripheral surface of the first busbar; a second insulating layer surrounding an outer peripheral surface of the second busbar; and a cap simultaneously enclosing the end portions of the first busbar and the second busbar that are adjacent to each other.

[0019] In one embodiment, the cap may include a partition disposed between the end of the first bus bar and the end of the second bus bar.

[0020] In one embodiment, the cap may include a first space and a second space separated by the partition wall, and the end of the first bus bar may be disposed in the first space, and the end of the second bus bar may be disposed in the second space.

[0021] In one embodiment, a plurality of caps may be provided at both ends of the first bus bar and the second bus bar, and the partition walls included in the plurality of caps may extend in the length direction of the first bus bar and be connected to each other.

[0022] In one embodiment, the partition wall may extend in a thickness direction of the first bus bar, and an end of the partition wall may protrude downward beyond the end of the first bus bar and the end of the second bus bar.

[0023] In one embodiment, the cap may further include protrusions protruding from the partition wall to the left and right, and upper surfaces of the protrusions may contact lower surfaces of the end portions of the first bus bar and the second bus bar.

[0024] In an embodiment, each of the first insulating layer and the second insulating layer may have a recessed groove formed therein, and the cap may include a fastener inserted into the groove.

[0025] In one embodiment, each of the first insulating layer and the second insulating layer may include a first portion that surrounds the body portion and a second portion that extends from the first portion, surrounds a portion of the end portion, and is covered by the cap.

[0026] In one embodiment, two grooves may be provided on the top surface of the first portion and may be formed adjacent to the second portion.

[0027] In one embodiment, the groove may be formed along an edge of the second portion.

[0028] In one embodiment, the first insulating layer and the second insulating layer may have higher elasticity than the cap.

[0029] In one embodiment, the insulating film may further include a glass fiber layer encasing the first insulating layer and the second insulating layer.

[0030] In one embodiment, the first insulating layer and the second insulating layer may comprise refractory silicon.

[0031] In one embodiment, the cap may include any one of fire-resistant plastic, mica, and fire-resistant silicone.

[0032] The battery pack of the present invention includes at least one busbar assembly; battery modules; a BDU (battery disconnect unit) module for controlling the electrical connection of the battery modules; and a BMS (Battery Management System) module for monitoring and controlling the operation of the battery modules, wherein the at least one busbar assembly electrically connects at least one of the battery modules, the battery modules and the BDU module, the battery modules and the BMS module, and the BDU module and the BMS module. [Effects of the Invention]

[0033] In the bus bar assembly of the present invention, the covering and cap of the bus bar maintain their shape even in the event of a fire, thereby improving insulation and fire resistance.

[0034] The effects of the present invention are not limited to those described above, and other effects not mentioned will be clearly understood by those skilled in the art from the claims. [Brief explanation of the drawings]

[0035] [Figure 1] 1A and 1B are exploded and assembled perspective views of a conventional busbar assembly; [Figure 2] FIG. 2 is a plan view of the battery pack according to the embodiment. [Figure 3] 3 is a perspective view of one of the battery modules included in the battery pack of FIG. 2. FIG. [Figure 4] 4 is a partial perspective view showing the battery module of FIG. 3 with a module frame and end plates removed. FIG. [Figure 5] FIG. 2 is a perspective view of a bus bar according to an embodiment. [Figure 6] FIG. 2 is a plan view of a bus bar provided with an insulating layer according to an embodiment. [Figure 7] FIG. 2 is a plan view of an embodiment of a busbar assembly. [Figure 8] FIG. 2 is a side view of an example busbar assembly. [Figure 9] FIG. 2 is a cross-sectional view of a busbar assembly according to an embodiment. [Figure 10] FIG. 2 is a cross-sectional view of a busbar assembly according to an embodiment. [Figure 11] FIG. 2 is a cross-sectional view of a busbar assembly according to an embodiment. [Figure 12] FIG. 2 is a plan view of an embodiment of a busbar assembly. [Figure 13] FIG. 2 is a plan view of an embodiment of a busbar assembly. [Figure 14] FIG. 2 is a plan view of an embodiment of a busbar assembly. [Figure 15] FIG. 2 is a plan view of a bus bar provided with an insulating layer according to an embodiment. [Figure 16] FIG. 2 is a plan view of an embodiment of a busbar assembly. [Figure 17] FIG. 2 is a side view of an example busbar assembly. [Figure 18] FIG. 2 is a cross-sectional view of a busbar assembly according to an embodiment. [Figure 19] FIG. 2 is a cross-sectional view of a busbar assembly according to an embodiment. [Figure 20]1 is a rear view of an embodiment of a busbar assembly. [Figure 21] FIG. 2 is a cross-sectional view of a busbar assembly according to an embodiment. [Figure 22] 1 is a rear view of an embodiment of a busbar assembly. DETAILED DESCRIPTION OF THE INVENTION

[0036] The present invention will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can easily implement various embodiments of the present invention. The present invention may be embodied in various different forms and is not limited to the examples described herein.

[0037] In order to clearly describe the present invention, parts that are not relevant to the description will be omitted and the same reference numerals will be used throughout the specification to refer to the same or similar components.

[0038] In addition, the size and thickness of each component shown in the drawings are arbitrarily shown for the convenience of explanation, and the present invention is not necessarily limited to those shown in the drawings. In the drawings, thicknesses are exaggerated to clearly show multiple layers and regions. In the drawings, thicknesses of some layers and regions are exaggerated for the convenience of explanation.

[0039] Furthermore, when a layer, film, region, plate, or other part is said to be "on" or "above" another part, this does not only mean that it is "directly above" that part, but also that there is another part in between. When a part is "directly above" another part, it means that there is no other part in the middle. Furthermore, when a part is "on" or "above" a reference part, it means that it is located above or below the reference part, and does not necessarily mean that it is located "above" or "above" the direction opposite to gravity.

[0040] Furthermore, throughout the specification, when a part "comprises" a certain element, it does not mean that it excludes other elements, but that it may further include other elements, unless otherwise specified.

[0041] Also, throughout the specification, "on a plane" means when the target part is viewed from above, and "on a cross section" means when the target part is cut vertically and viewed from the side.

[0042] Furthermore, throughout the specification, the first direction (DR1), the second direction (DR2), and the third direction (DR3) are used as relative concepts. The first direction (DR1), the second direction (DR2), and the third direction (DR3) can intersect perpendicularly with each other. Throughout this specification, the concepts of up and down have been described as being distinguished along the third direction (DR3). Specifically, the up direction or upper direction refers to the third direction (DR3). The down direction or lower direction refers to the opposite direction of the third direction (DR3). In this specification, "thickness" refers to the length measured from the third direction (DR3).

[0043] FIG. 2 is a plan view of the battery pack of one embodiment.

[0044] 2 , a battery pack 1000 according to one embodiment includes a busbar assembly 100, a pack frame 1100, battery modules 1200, a battery disconnect unit (BDU) module 1300 for controlling the electrical connection of the battery modules 1200, and a battery management system (BMS) module 1400 for monitoring and controlling the operation of the battery modules 1200. At least one busbar assembly 100 according to this embodiment electrically connects at least one of the battery modules 1200 together, the battery modules 1200 and the BDU module 1300 together, the battery modules 1200 and the BMS module 1400 together, and the BDU module 1300 and the BMS module 1400 together. Specifically, a plurality of battery modules 1200 can be housed in the pack frame 1100, and the busbar assembly 100 can electrically connect the battery modules 1200 together and the battery modules 1200 and the BDU module 1300 together. That is, the bus bar assembly 100 according to this embodiment can serve as an HV (High Voltage) connection. Here, the HV connection is a connection that serves as a power source for supplying power that requires high voltage, and refers to a connection between battery cells or between battery modules.

[0045] Meanwhile, the BDU module 1300 is a component for controlling the electrical connection of the battery module 1200, and can cut off the power supply between the power conversion device and the battery module 1200. The BDU module 1300 can ensure the safety of the battery pack 1000 by cutting off the power supply to the battery pack 1000 when a condition occurs in which the current exceeds a set range.

[0046] Meanwhile, the LV connection member 100′ according to this embodiment may be responsible for electrical connection between the battery module 1200 and the BMS module 1400. The electrical connection here is a low voltage (LV) connection, which means a sensing connection for detecting and controlling the voltage and temperature of the battery module 1200. Specifically, sensors and the like are disposed inside the battery module 1200, and real-time temperature and voltage information of the battery module 1200 is transmitted to the BMS module 1400 via the LV connection member 100′. The real-time operating status of the battery module 1200 can be monitored and controlled via the BMS module 1400. Although not specifically shown, an HV current sensor may be integrated into the BMS module 1400. In this case, the busbar assembly according to this embodiment may be responsible for electrical connection between the battery module 1200 and the BMS module 1400 or between the BDU module 1300 and the BMS module 1400.

[0047] 3 and 4, a battery module 1200 according to this embodiment will be described. However, the battery module 1200 described below is one exemplary structure of a battery module including a plurality of battery cells 11, and various types of battery modules including a plurality of battery cells can be applied.

[0048] FIG. 3 is a perspective view showing one of the battery modules included in the battery pack of FIG.

[0049] FIG. 4 is a partial perspective view showing the battery module of FIG. 3 with the module frame and end plates removed.

[0050] 3 and 4, a battery module 1200 according to this embodiment may include a battery cell stack 11A in which a plurality of battery cells 11 are stacked. The battery cell stack 11A is shown in Fig. 4. The battery cell stack 11A may be housed in a module frame 30 and end plates 40.

[0051] The battery cells 11 may be pouch-type battery cells. Such pouch-type battery cells may be formed by encapsulating an electrode assembly in a pouch case made of a laminate sheet including a resin layer and a metal layer, and then fusing the outer periphery of the pouch case. Such battery cells 11 may be formed in a rectangular sheet structure. Electrode leads 11L connected to the electrode assembly protrude from the pouch case, and the electrode leads 11L of each battery cell 11 may be electrically connected to each other via a lead bus bar 21. Meanwhile, at least one electrode lead 11L may be connected to a terminal bus bar 22. A portion of the terminal bus bar 22 may be exposed to the outside of the battery module 1200, as shown in FIG. 3 . The lead bus bar 21 and the terminal bus bar 22 may both include a metal material with excellent electrical conductivity.

[0052] The busbar assembly 100 according to this embodiment is electrically connected to the terminal busbar 22, thereby enabling the above-described HV connection. That is, the battery module 1200 can be electrically connected to another battery module 1200, a BDU module 1300, or a BMS module 1400 via the busbar assembly 100 connected to the terminal busbar 22.

[0053] A busbar assembly according to one embodiment will now be described.

[0054] FIG. 5 is a perspective view of a bus bar according to an embodiment.

[0055] Referring to FIG. 5, the bus bar 200 guides electrical connections within the battery pack 1000 (see FIG. 2). The bus bar 200 is a component for guiding electrical connections, i.e., HV connections, of the battery modules 1200 (see FIG. 2), and may include a metal material with excellent electrical conductivity. For example, the bus bar 200 may include a copper (Cu) material. The body portion 210 may have a rod shape extending in one direction. In FIG. 2, the bus bar 200 is illustrated as having a rod shape extending in a first direction (DR1) as an example.

[0056] In one embodiment, busbar 200 includes a body portion 210 and end portions 220. Body portion 210 may correspond to a central portion of busbar 200. End portions 220 extend from both ends of body portion 210. For example, end portions 220 may extend from both ends of body portion 210 in a first direction (DR1) and in a direction opposite to the first direction (DR1). For convenience, busbar 200 has been described herein as including body portion 210 and end portions 220, but body portion 210 and end portions 220 have an integral shape.

[0057] The end 220 has through holes (HH) defined therein. Fastening members can be inserted into the through holes (HH) to connect the bus bar 200 to an external electrical device. For example, bolts can be inserted into the through holes (HH) of the end 220 to connect the bus bar 200 to a terminal bus bar 22 (see FIG. 3) of a battery module 1200 (see FIG. 3). FIG. 6 is a perspective view of a busbar provided with an insulating layer according to one embodiment.

[0058] 6, the insulating layer 300 is provided to encase the body portion 210 (see FIG. 5) of the bus bar 200. That is, the insulating layer 300 is provided to insulate the body portion 210 (see FIG. 5). At this time, at least a portion of the end portion 220 is exposed from the insulating layer 300 and can be electrically connected to the terminal bus bar 22 (see FIG. 3) of the battery module 1200 (see FIG. 3).

[0059] The insulating layer 300 may include a first portion 310 that encloses the body portion 210 (see FIG. 5 ) of the bus bar 200 and a second portion 320 that encloses a portion of the end portion 220. The first portion 310 may surround the outer periphery of the body portion 210 of the bus bar 200. The second portion 320 extends from both ends of the first portion 310 and is covered by a cap 400 (described later). The second portion 320 extends in opposite directions from both ends of the first portion 310. Specifically, the second portion 320 extends from one end of the first portion 310 in a first direction (DR1) and from the other end of the first portion 310 in the opposite direction to the first direction (DR1). The second portion 320 of the insulating layer 300 covers a portion of the end portion 220, thereby preventing the bus bar 200 from being exposed between the insulating layer 300 and the cap 400 (described later). Furthermore, the insulating layer 300 includes the second portion 320, and can ensure the insulation distance of the bus bar 200.

[0060] Meanwhile, a groove (GV) having a recessed shape is formed in the insulating layer 300. In one embodiment, the groove (GV) may be formed on the upper surface of the first portion 310 and adjacent to the second portion 320. Two grooves (GV) may be provided, one at each end of the first portion 310. Because the groove (GV) has a recessed shape, an external fastener can be inserted into the groove (GV). Specifically, the cap 400 (see FIG. 7), which will be described later, may include a fastener inserted into the groove (GV).

[0061] The insulating layer 300 may also include refractory silicone. For example, the insulating layer 300 may be formed by molding refractory silicone on the outer periphery of the body portion 210 (FIG. 5) of the bus bar 200. Unlike typical silicone materials that burn when exposed to flames or high heat, refractory silicone can be ceramified at high heat. Therefore, when exposed to flames, refractory silicone is ceramified without burning, thereby maintaining the insulation properties of the bus bar 200. For example, refractory silicone may be ceramified at temperatures between 500°C and 1700°C. However, the temperature range at which refractory silicone ceramifies is not limited thereto. The refractory silicone may include a silicone polymer and silica. For example, the silicone polymer may be a polysiloxane-based compound having a vinyl group as a functional group, which may serve as a base material for the refractory silicone material. For example, the silica used may be a reinforcing filler in silicone polymers, and may be fumed silica. High-purity silicon chloride (SiCl4) compounds can be produced from silicon metal as the main raw material through a reaction with hydrochloric acid and a purification process. Fumed silica can be obtained by reacting this with hydrogen and oxygen in a high-temperature flame. Refractory silicon can also contain platinum (Pt) as a catalyst.

[0062] When refractory silicone is exposed to flame or high heat, the silicone polymer decomposes and the silica (SiO2) cross-links to form a ceramic material. In one embodiment, insulating layer 300 containing refractory silicone can be ceramified and maintain its electrical insulation properties even when exposed to flame or in a high-heat environment, without burning or melting.

[0063] Therefore, the insulating layer 300 insulates the body portion 210 (see FIG. 5) of the bus bar 200 even in the presence of flames or high temperatures, and can prevent the bus bar 200 from coming into contact with other electrical equipment or conductive members, causing a short circuit.

[0064] A busbar assembly according to one embodiment will be described with reference to FIGS.

[0065] FIG. 7 is a plan view of a busbar assembly according to one embodiment.

[0066] FIG. 8 is a side view of a busbar assembly according to one embodiment.

[0067] 9 to 11 are cross-sectional views of a busbar assembly according to an embodiment.

[0068] 7 to 11, for ease of explanation, caps 400 are provided on one ends 220a, 220b of bus bars 200a, 200b, and one end 220a, 220b is shown without caps 400. However, this is for the purpose of explanation, and the bus bar assembly 100 of the present invention includes caps 400 provided on both ends 220a, 220b of bus bars 200a, 200b, as shown in FIG.

[0069] Referring to FIG. 7, the bus bar assembly 100 of one embodiment includes a plurality of bus bars 200 a , 200 b , insulating layers 300 a , 300 b , and a cap 400 .

[0070] The multiple bus bars 200a, 200b include a first bus bar 200a and a second bus bar 200b arranged to face each other. The first bus bar 200a connects the first battery module 1200a and the second battery module 1200b, and the second bus bar 200b connects the third battery module 1200c and the fourth battery module 1200d. In this case, the third battery module 1200c faces the first battery module 1200a, and the fourth battery module 1200d faces the second battery module 1200b, and the first bus bar 200a and the second bus bar 200b are arranged to face each other. Meanwhile, the above description of the bus bar 200 applies equally to each of the first bus bar 200a and the second bus bar 200b.

[0071] The bus bar assembly 100 includes a first insulating layer 300a surrounding the outer periphery of the first bus bar 200a and a second insulating layer 300b surrounding the outer periphery of the second bus bar 200b. The above description of the insulating layer 300 also applies to the first insulating layer 300a and the second insulating layer 300b.

[0072] The cap 400 is provided to insulate the ends 220a, 220b of the bus bars 200a, 200b. The cap 400 according to an embodiment of the present invention simultaneously covers both ends of the first bus bar 200a and the second bus bar 200b. Specifically, the cap 400 simultaneously covers one end 220a of the first bus bar 200a and one end of the opposing second bus bar 200b. By simultaneously covering the adjacent ends 220a, 220b, the cap 400 can effectively insulate the adjacent bus bars 200a, 200b even if the bus bars 200a, 200b are larger than the distance between the battery modules 1200a, 1200b, 1200c, and 1200d.

[0073] 7, 8, and 11, a cap 400 according to one embodiment includes a main body 410, a fastening portion 420, and a partition wall 430. The main body 410 is a portion that encases the end portions 220a, 220b. The main body 410 encases the second portions 320a, 320b of the insulating layers 300a, 300b, and the cap 400 is coupled to the insulating layers 300a, 300b. The fastening portion 420 is a portion that extends from the main body 410. The fastening portion 420 extends from the end portions 220a, 220b of the bus bars 200a, 200b toward the body portions 210a, 210b and can be inserted into grooves (GVs) formed in the insulating layers 300a, 300b. The fastening portion 420 is inserted into the grooves (GV) of the insulating layers 300a and 300b, so that the cap 400 can be stably fixed to the insulating layers 300a and 300b without swinging left and right.

[0074] In this case, the grooves (GV) can be formed in the third portions 330a, 330b extending upward from the top surfaces of the first portions 310a, 310b of the insulating layers 300a, 300b, thereby ensuring a sufficient depth. If the third portions 330a, 330b were omitted and the grooves (GV) were formed directly on the top surfaces of the first portions 310a, 310b of the insulating layers 300a, 300b, it may be difficult to ensure a sufficient depth of the grooves (GV) due to the body portions 210a, 210b disposed inside the insulating layers 300a, 300b.

[0075] Alternatively, the first insulating layer 300a and the second insulating layer 300b may each be formed by extruding the first portions 310a and 310b, the second portions 320a and 320b, and the third portions 330a and 330b in an integrated shape.

[0076] 7 to 10 , partition wall 430 is disposed between one end 220a of first bus bar 200a and one end 220b of second bus bar 200b. Partition wall 430 may extend in a first direction (DR1), which is the length direction of first bus bar 200a, and may insulate one end 220a of first bus bar 200a from one end 220b of second bus bar 200b. The interior of cap 400 is divided into a first space (SP1) and a second space (SP2) by partition wall 430. One end 220a of first bus bar 200a is disposed in first space (SP1), and one end 220b of second bus bar 200b is disposed in second space (SP2). Fastening members such as bolts may be stored in the first space (SP1) and the second space (SP2) during a subsequent assembly process.

[0077] In addition, the partition wall 430 extends in the thickness direction of the first bus bar 200a, and the end of the partition wall 430 may protrude downward from the ends 220a and 220b, thereby ensuring an insulation distance (ID) between the ends 220a and 220b and improving the insulation of the bus bar assembly 100.

[0078] Meanwhile, the thicknesses of the main body 410 and the partition wall 430 can be set so that they contact the second portion 320b, as shown in Fig. 10. As a result, in the cross-sectional view of Fig. 9, in which the second portion 320b does not exist, there may be a separation space between the ends 220a, 220b and the main body 410, and between the ends 220a, 220b and the partition wall 430. However, Fig. 9 shows only one example, and the thickness can be adjusted as necessary so that the main body 410 and the partition wall 430 contact the ends 220a, 220b even in Fig. 9.

[0079] In one embodiment, the cap 400 may include any one of fire-resistant plastic, mica, and fire-resistant silicone, thereby allowing the cap 400 to exhibit excellent fire resistance.

[0080] Fire-resistant plastics can block the flames without developing holes or drips for a certain period of time when exposed to fire. Specifically, fire-resistant plastics can protect the internal structure by forming a carbonized layer in the flame. Fire-resistant plastics can include at least one of PPO (Polyphenylene Oxide)-based materials, PA (Polyamide)-based materials, and PBT (Polybutylene Terephthalate)-based materials.

[0081] Mica has excellent fire resistance, heat resistance, high temperature resistance and electrical insulation properties, so it can act as a fire-resistant insulating layer without burning in flames or high heat.

[0082] In one embodiment, the elasticity of the insulating layers 300a and 300b may be greater than the elasticity of the cap 400. The elasticity of the insulating layers 300a and 300b allows the cap 400 to be firmly fixed to the insulating layers 300a and 300b without the need for a separate adhesive layer. Specifically, when the cap 400 is tightly fitted into the grooves (GVs) formed in the insulating layers 300a and 300b, the insulating layers 300a and 300b, which have relatively high elasticity, are compressed, allowing the cap 400 to be inserted into the grooves (GVs). After insertion, the cap 400 can be fixed in the grooves (GVs) due to the elasticity of the insulating layers 300a and 300b. Therefore, the conventional tape (AL, see FIG. 1) used to fix the cap 400 to the insulating layers 300a and 300b may be omitted.

[0083] FIG. 12 is a plan view of a busbar assembly according to one embodiment.

[0084] 12 shows that the first bus bar 200a and the second bus bar 200b have been provided with caps 400 on either end. FIG. 12 shows the final structure of the bus bar assembly 100 shown in FIG.

[0085] Referring to FIG. 12, each of the caps 400 includes a partition wall 430, which can insulate the sides of the end 220a of the first bus bar 200a and the end 220b of the second bus bar 200b, which are arranged adjacent to each other.

[0086] FIG. 13 is a plan view of a busbar assembly according to one embodiment.

[0087] 13, the bus bar assembly 100-1 according to an embodiment may include a cap 400-1 provided on each end of the first bus bar 200a and the second bus bar 200b. Specifically, the partition walls 430 included in the caps 400 provided on each end of the bus bar 200a and the second bus bar 200b in FIG. 12 may be connected to each other to form a partition wall 430-1 having an integral shape. In this case, the sides of the first bus bar 200a and the second bus bar 200b, which are arranged adjacent to each other, may be completely insulated.

[0088] FIG. 14 is a plan view of a bus bar assembly according to one embodiment.

[0089] Referring to FIG. 14 , the busbar assembly 100-2 according to an embodiment may further include a glass fiber layer 500. The glass fiber layer 500 may include a first glass fiber layer 500a encasing the first insulating layer 300a and a second glass fiber layer 500b encasing the second insulating layer 300b. The glass fiber layers 500a and 500b may also provide physical protection for the internal structure. For example, the glass fiber layers 500a and 500b may prevent the insulating layers 300a and 300b from being directly exposed to an external flame. If the insulating layers 300a and 300b are ceramized in a flame or high-heat environment, the electrical insulation of the insulating layers 300a and 300b may be maintained, but their strength may be weakened and they may be crushed by external forces. The glass fiber layers 500a, 500b are provided to wrap the insulating layers 300a, 300b and prevent the insulating layers 300a, 300b from being crushed by external forces. For example, the glass fiber layers 500a, 500b may be provided in the form of a glass fiber tape and wound multiple times on the insulating layers 300a, 300b. The bus bar assembly 100-2 of the present embodiment includes the glass fiber layer 500, which improves structural rigidity and maintains excellent insulation performance even in the event of a fire.

[0090] However, the busbar assembly of the present invention is not limited to the above embodiments.

[0091] FIG. 15 is a plan view of a bus bar provided with an insulating layer according to one embodiment.

[0092] 15, an insulating layer 300-1 according to an embodiment may be provided on a bus bar 200. For ease of explanation, a cap 400-2 is provided only on one end 220 of the bus bar 200, and the other end 220 is shown as being exposed and not provided with a cap 400-2.

[0093] The insulating layer 300-1 may include a first portion 310 that encases the body portion 210 (see FIG. 5) of the bus bar 200 and a second portion 320-1 that encases a part of the end portion 220. The insulating layer 300-1 may be provided by injection molding so that the first portion 310 and the second portion 320-1 have an integral shape.

[0094] A recessed groove GV-1 is formed in the insulating layer 300-1. In one embodiment, the groove GV-1 may be formed along an edge of the second portion 320-1 of the insulating layer 300-1 and adjacent to the first portion 310. Two grooves GV-1 may be provided, one formed in each of the first portions 310 at both ends. A cap 400-2 (described below) may be fixed to the insulating layer 300-1 by having at least a portion inserted into the groove GV-1 when provided on the second portion 320-1.

[0095] 16 to 22, a bus bar assembly 100-3 to which the bus bar 200 and insulating layer 300-1 of FIG. 15 are applied will be described.

[0096] FIG. 16 is a plan view of a bus bar assembly according to one embodiment.

[0097] FIG. 17 is a side view of an embodiment of a busbar assembly.

[0098] FIG. 18 is a cross-sectional view of a busbar assembly according to one embodiment.

[0099] FIG. 19 is a cross-sectional view of a busbar assembly according to one embodiment.

[0100] FIG. 20 is a rear view of an embodiment of a busbar assembly.

[0101] 16 to 22, for ease of explanation, caps 400-2 are provided on one ends 220a and 220b of bus bars 200a and 200b, and one end 220a and 220b is shown without caps 400-2. However, this is for the purpose of explanation, and bus bar assembly 100-3 of the present invention includes two caps 400-2 provided on both ends 220a and 220b of bus bars 200a and 200b.

[0102] Referring to FIG. 16, a bus bar assembly 100-3 according to one embodiment includes a first bus bar 200a, a second bus bar 200b, insulating layers 300a-1 and 300b-1, and a cap 400-2.

[0103] The same applies to first bus bar 200a and second bus bar 200b as described above with reference to FIG.

[0104] The insulating layers 300a-1 and 300b-1 include a first insulating layer 300a-1 that surrounds the outer periphery of the first bus bar 200a and a second insulating layer 300b-1 that surrounds the outer periphery of the second bus bar 200b. The same description of the insulating layer 300-1 described above with reference to FIG. 15 applies to the first insulating layer 300a-1 and the second insulating layer 300b-1.

[0105] The cap 400-2 is provided to insulate the ends 220a and 220b of the bus bars 200a and 200b. According to an embodiment of the present invention, the cap 400-2 simultaneously covers both the ends of the first bus bar 200a and the second bus bar 200b. Specifically, the cap 400-2 simultaneously covers both the end 220a of the first bus bar 200a and the opposite end 220b of the second bus bar 200b. By simultaneously covering the adjacent ends 220a and 220b, the cap 400-2 can effectively insulate the adjacent bus bars 200a and 200b, even if the bus bars 200a and 200b are larger than the distance between the battery modules (1200a, 1200b, 1200c, and 1200d).

[0106] 7 can be applied to the material of the cap 400-2. That is, the cap 400-2 can include one of fire-resistant plastic, mica, and fire-resistant silicone. Also, the elasticity of the insulating layers 300a and 300b can be greater than the elasticity of the cap 400.

[0107] 16 to 20, cap 400-2 according to an embodiment includes a main body 410 and a partition wall 430. That is, compared to caps 400 and 400-1 according to an embodiment described above with reference to FIGS. 7 to 14, cap 400-2 does not include fastening portion 420 (see FIG. 8). This is because the method of coupling cap 400-2 and insulating layers 300a-1 and 300b-1 is different from the method described with reference to FIGS. 7 to 14.

[0108] The main body 410 of the cap 400-2 encases the end portions 220a, 220b and the second portions 320a-1, 320b-1 of the insulating layers 300a-1, 300b-1, and is bonded to the insulating layers 300a-1, 300b-1. Specifically, referring to FIG. 18, when the main body 410 encases the second portions 320a-1, 320b-1, a portion of the main body 410 is inserted into the groove (GV-1). This allows the main body 410 to be stably bonded to the insulating layers 300a-1, 300b-1 without peeling. This eliminates the need for a conventional cap fixing tape (AL, see FIG. 1).

[0109] 16, 17, and 19, a partition wall 430 is disposed between one end 220a of the first bus bar 200a and one end 220b of the second bus bar 200b. The partition wall 430 may extend in a first direction (DR1), which is the length direction of the first bus bar 200a, and may insulate one end 220a of the first bus bar 200a from one end 220b of the second bus bar 200b. The interior of the cap 400 is divided into a first space (SP1) and a second space (SP2) by the partition wall 430. The one end 220a of the first bus bar 200a is disposed in the first space (SP1), and the one end 220b of the second bus bar 200b is disposed in the second space (SP2). In addition, a bolt (BT) may be housed in each of the first space (SP1) and the second space (SP2). The bolts (BT) are inserted into the through holes (HH) to fix the ends 220a and 220b to the battery modules (1200a, 1200a, 1200a, 1200d).

[0110] In addition, the partition wall 430 extends in the thickness direction of the first bus bar 200a, and the end of the partition wall 430 may protrude downward from the ends 220a and 220b, thereby ensuring an insulation distance (ID) between the ends 220a and 220b and improving the insulation of the bus bar assembly 100.

[0111] 19, there may be a space between the ends 220a, 220b and the main body 410, and between the ends 220a, 220b and the partition wall 430. However, this is just one example, and as described above with reference to FIG. 9, the thickness may be adjusted as needed, and the main body 410 and the partition wall 430 may be deformed so as to contact the ends 220a, 220b.

[0112] 20, the body 410 is provided to contact the outer surfaces of the insulating layers 300a-1 and 300b-1. Therefore, a space may exist between the body 410 and the ends 220a and 220b on the rear surface. In FIG. 20, the inner surface of the body 410 is shown as being visible from the rear surface through the space. However, this embodiment is not limited thereto, and the body 410 may be provided to contact the ends 220a and 220b. The partition wall 430 may be disposed between the ends 220a and 220b to insulate the ends 220a and 220b from each other.

[0113] However, the embodiment of the cap 400-2 is not limited to this.

[0114] FIG. 21 is a cross-sectional view of a busbar assembly according to one embodiment.

[0115] FIG. 22 is a rear view of an embodiment of a busbar assembly.

[0116] 21 and 22, the cap 400-3 according to an embodiment may further include a protrusion 440 protruding from the partition 430. A plurality of protrusions 440 may be provided, protruding from each of the left and right sides of the partition 430. Specifically, the protrusions 440 may protrude from the partition 430 toward the ends 220a and 220b. The upper surfaces of the protrusions 440 contact the lower surfaces of the ends 220a and 220b, thereby preventing the cap 400-3 from peeling upward. In this case, the cap 400-3 may include a material such as refractory silicone and have a predetermined elasticity. During assembly, when the cap 400-3 is fastened to the ends 220a and 220b from top to bottom, the protrusion 440 is temporarily compressed by the ends 220a and 220b, and after fastening is complete, the shape of the protrusion 440 is restored so that the upper surface of the protrusion 440 contacts the lower surface of the ends 220a and 220b. Although not shown, the protrusion 440 may also be applied to the cap 400 included in the busbar assembly 100 described in FIG. 7.

[0117] 13 may also be applied to the bus bar assembly 100-3 described above with reference to Figures 16 to 22. That is, the two caps 400-2 included in the bus bar assembly 100-3 may have an integrated shape with the partition walls 430 connected to each other. This allows the sides of the first bus bar 200a and the second bus bar 200b, which are arranged adjacent to each other, to be completely insulated.

[0118] 14 may also be applied to the bus bar assembly 100-3 described above with reference to FIGS. 16 to 22. That is, the bus bar assembly 100-3 may further include a glass fiber layer 500. The glass fiber layer 500 may include a first glass fiber layer 500a that wraps the first portion 310a of the first insulating layer 300a, and a second glass fiber layer 500b that wraps the first portion 310b of the second insulating layer 300b.

[0119] The busbar assembly of the present invention includes a cap that simultaneously covers the ends of adjacently arranged first and second busbars, and can effectively insulate adjacent busbars even if the busbars are large compared to the distance between battery modules. This makes it possible to provide a busbar assembly with a simpler structure than conventional ones and improved insulation and fire resistance.

[0120] In this embodiment, terms indicating directions such as front, back, left, right, up, and down are used, but these terms are used only for convenience of explanation and may change depending on the position of the object of interest, the position of the observer, etc.

[0121] One or more battery modules according to the above-described embodiments may be mounted together with various control and protection systems such as a BMS (Battery Management System), a BDU (Battery Disconnect Unit), and a cooling system to form a battery pack.

[0122] The battery module or battery pack can be applied to various devices, specifically, but not limited to, transportation means such as electric bicycles, electric cars, and hybrids, and ESS (Energy Storage Systems).

[0123] Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the claims below also fall within the scope of the present invention. [Explanation of symbols]

[0124] 100 Busbar Assembly 200 Busbar 200a 1st bus bar 200b Second bus bar 210 Body 220 End 300 insulating layer 300a First insulating layer 300b Second insulating layer 310 Part 1 320 Part 2 330 3 parts 400 caps 410 Main Unit 420 Fastening part 430 Bulkhead 500 fiberglass layers 1000 battery packs 1100 pack frame 1200 battery module 1300 BDU Module 1400 BMS Module

Claims

1. a first bus bar and a second bus bar arranged alongside one another, each of the first bus bar and the second bus bar including a body portion and ends extending from opposite ends of the body portion and having through holes defined therein; a first insulating layer surrounding an outer circumferential surface of the first bus bar; a second insulating layer surrounding the outer circumferential surface of the second bus bar; and a cap that simultaneously encloses the end of the first bus bar and the end of the second bus bar that are adjacent to each other; a busbar assembly including:

2. The bus bar assembly of claim 1 , wherein the cap includes a partition disposed between the end of the first bus bar and the end of the second bus bar.

3. the cap includes a first space and a second space separated by the partition; the end of the first bus bar is disposed in the first space, The bus bar assembly according to claim 2 , wherein the end of the second bus bar is disposed in the second space.

4. a plurality of caps are provided on both ends of the first bus bar and the second bus bar; The bus bar assembly of claim 2 , wherein the partition walls included in the plurality of caps extend in a length direction of the first bus bar and are connected to each other.

5. The bus bar assembly according to claim 2 , wherein the partition wall extends in a thickness direction of the first bus bar, and an end of the partition wall protrudes downward beyond the end of the first bus bar and the end of the second bus bar.

6. The cap further includes protrusions protruding from the partition wall to the left and right, The bus bar assembly according to claim 5 , wherein an upper surface of the protrusion contacts a lower surface of the end of the first bus bar and a lower surface of the end of the second bus bar.

7. a recessed groove is formed in each of the first insulating layer and the second insulating layer; The busbar assembly according to any one of claims 1 to 6, wherein the cap includes a fastening portion that is inserted into the groove.

8. Each of the first insulating layer and the second insulating layer is 8. The bus bar assembly of claim 7, further comprising a first portion encasing said body portion, and a second portion extending from said first portion, encasing a portion of said end portion, and being covered by said cap.

9. The busbar assembly according to claim 8 , wherein two grooves are provided on the upper surface of the first portion and are formed adjacent to the second portion.

10. The busbar assembly of claim 8 , wherein the groove is formed along an end of the second portion.

11. The busbar assembly according to claim 1 , wherein the first insulating layer and the second insulating layer have higher elasticity than the cap.

12. The busbar assembly of claim 1 , further comprising a fiberglass layer encasing the first insulating layer and the second insulating layer.

13. The busbar assembly of claim 1 , wherein the first insulating layer and the second insulating layer comprise refractory silicone.

14. The busbar assembly according to claim 1 , wherein the cap comprises one of a fire-resistant plastic, mica, and fire-resistant silicone.

15. At least one busbar assembly according to claim 1; Battery module; a battery disconnect unit (BDU) module for controlling the electrical connection of the battery module; and A BMS (Battery Management System) module that monitors and controls the operation of the battery module. Including, The at least one busbar assembly electrically connects at least one of the battery modules, the battery modules and the BDU module, the battery modules and the BMS module, and the BDU module and the BMS module.

Images