Busbar assembly and battery pack including same

Abstract

A busbar assembly according to one embodiment of the present invention includes a busbar including a main body portion and end portions extending from both ends of the main body portion and having through holes formed therein; an insulating layer surrounding the main body portion and having a recessed groove formed therein; and a cap inserted into the groove and surrounding the end portions, wherein the insulating layer has higher elasticity than the cap.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0079552, filed on June 21, 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, as the use of portable devices such as mobile phones, laptops, video cameras, and digital cameras has become commonplace, there has been 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 air pollution caused by existing gasoline-powered vehicles that use fossil fuels, and so 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 because they have the advantages of being free to charge and discharge as they have almost no memory effect compared to nickel-based secondary batteries, a very low self-discharge rate, and a 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 a positive electrode plate and a negative electrode plate, each coated with the positive and negative electrode active materials, are arranged with a separator sandwiched therebetween, 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 to three battery cells, secondary batteries used in medium- to large-sized devices such as automobiles typically use battery modules in which multiple battery cells are electrically connected. These battery modules improve capacity and output by connecting multiple battery cells in series or parallel to form a stack of battery cells. One or more battery modules can also be integrated 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 by the multiple battery cells can be combined in a small space, causing a rapid and excessive rise in temperature. In other words, a battery module made up of multiple stacked battery cells and a battery pack equipped with these battery modules can produce high output, but if the battery cells do not properly dissipate heat or if thermal runaway occurs in the battery cells, there is a high possibility of continuous fires and 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 an HV (High Voltage) connection in a battery pack. 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 be made of copper (Cu).

[0012] A coating 20C may surround the busbar 20. The coating 20C may include an electrically insulating material, such as silicone or epoxy. Because the coating 20C surrounds the busbar 20, through which a high current flows, the busbar 20 is prevented from coming into contact with other electrical components or conductive members other than the terminal busbars of the battery module, thereby preventing a short circuit.

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

[0014] However, when a fire breaks out inside a battery pack, the flame reaches a temperature of approximately 1000°C, which is extremely high, and may melt the coating 20C surrounding the busbar 20, or melt the cap CP and tape AL, exposing the busbar 20. If the exposed busbar 20 comes into contact with another conductive member and a short circuit occurs, the internal flame may further spread 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 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 busbar including a main body portion and end portions extending from both ends of the main body portion and having through holes formed therein; an insulating layer surrounding the main body portion and having a recessed groove formed therein; and a cap inserted into the groove and surrounding the end portions, wherein the insulating layer has higher elasticity than the cap.

[0019] The insulating layer may include a first portion surrounding the main body portion, and a second portion extending from the first portion to surround a part of the end portion and covered by the cap.

[0020] Two of the grooves may be provided on the top surface of the first portion and may be formed adjacent to the second portion.

[0021] The cap may include a fastening portion at least partially protruding toward the body portion and inserted into the groove.

[0022] The groove may be formed along a periphery of the second portion, the groove being adjacent to the first portion.

[0023] The cap may be at least partially inserted into the groove while covering the second portion.

[0024] The first portion may surround an outer circumferential surface of the bus bar.

[0025] The second portion may surround a top surface and a side surface of the bus bar.

[0026] The cap may cover at least a portion of a lower surface of the bus bar.

[0027] The insulating layer may further include a glass fiber layer surrounding the insulating layer.

[0028] The insulating layer may comprise silicon that ceramizes at high temperatures.

[0029] The cap may comprise a fire-resistant plastic.

[0030] The battery pack of the present invention includes at least one busbar assembly, battery modules, a BDU (battery disconnect unit) module for controlling electrical connection of the battery modules, and a BMS (Battery Management System) module for monitoring and controlling 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]

[0031] 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 properties and fire resistance.

[0032] The effects of the present invention are not limited to the effects described above, and other effects not mentioned will be clearly understood by those skilled in the art from the description of the claims. [Brief explanation of the drawings]

[0033] [Figure 1] 1A and 1B are exploded and assembled perspective views of a conventional bus bar 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 the busbar assembly according to the embodiment. [Figure 8] FIG. 2 is a side view of the busbar assembly of one embodiment. [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 cross-sectional view of a busbar assembly according to an embodiment. [Figure 13] FIG. 2 is a plan view of the busbar assembly according to the embodiment. [Figure 14] FIG. 2 is a plan view of the busbar assembly according to the embodiment. [Figure 15] FIG. 2 is a plan view of the busbar assembly according to the embodiment. [Figure 16] FIG. 2 is a side view of the busbar assembly of one embodiment. [Figure 17] FIG. 2 is a rear view of the busbar assembly of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0034] DETAILED DESCRIPTION OF THE INVENTION The present invention may, however, be embodied in various different forms and should not be construed as being limited to the embodiments set forth herein.

[0035] In order to clearly explain the present invention, parts that are not necessary for the explanation are omitted, and the same reference numerals are used throughout the specification to refer to the same or similar components.

[0036] Furthermore, 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, 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.

[0037] Furthermore, when a layer, film, region, plate, or other part is said to be "on" or "above" another part, this includes not only the case where it is "directly above" the other part, but also the case where there is another part in between. When a part is said to be "directly above" another part, it means that there is no other part in between. Furthermore, being "on" or "above" a reference part means being located above or below the reference part, and does not necessarily mean being located "on" or "above" the direction opposite to gravity.

[0038] Also, throughout the specification, when a part is said to "comprise" a certain element, this means that it can further include other elements, rather than excluding other elements, unless otherwise specified.

[0039] Also, throughout the specification, "on a plane" means when the subject part is viewed from above, and "on a cross section" means when the subject part is cut vertically and viewed from the side.

[0040] Furthermore, throughout the specification, the first direction DR1, the second direction DR2, and the third direction DR3 are used in a relative sense. The first direction DR1, the second direction DR2, and the third direction DR3 may intersect perpendicularly with each other. Throughout the specification, the concepts of up and down are described as being defined along the third direction DR3. Specifically, the upper or upper direction refers to the third direction DR3. The lower or lower direction refers to the opposite direction of the third direction DR3. In the specification, "thickness" refers to the length measured in the third direction DR3.

[0041] FIG. 2 is a plan view of the battery pack of one embodiment.

[0042] 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 electrical connection between 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 an embodiment of the present invention 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 may be housed in the pack frame 1100, and the busbar assembly 100 may electrically connect the battery modules 1200 together and the battery modules 1200 and the BDU module 1300 together. That is, the busbar assembly 100 according to an embodiment of the present invention can serve as an HV (High Voltage) connection. Here, the HV connection refers to 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.

[0043] 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.

[0044] Meanwhile, the LV connecting member 100′ according to an embodiment of the present invention may provide electrical connection between the battery module 1200 and the BMS module 1400. The electrical connection here is a low voltage (LV) connection, which refers to a sensing connection for detecting and controlling the voltage and temperature of the battery module 1200. Specifically, sensors 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 through the LV connecting member 100′. The real-time operating status of the battery module 1200 can be monitored and controlled through 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 an embodiment of the present invention may provide electrical connection between the battery module 1200 and the BMS module 1400 or between the BDU module 1300 and the BMS module 1400.

[0045] A battery module 1200 according to an embodiment of the present invention will be described with reference to FIGS.

[0046] 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.

[0047] FIG. 3 is a perspective view showing one of the battery modules included in the battery pack of FIG.

[0048] FIG. 4 is a partial perspective view showing the battery module of FIG. 3 with the module frame and end plates removed.

[0049] 3 and 4, a battery module 1200 according to an embodiment of the present invention 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. Such a battery cell stack 11A may be housed in a module frame 30 and end plates 40.

[0050] 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 have 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 . Both the lead bus bar 21 and the terminal bus bar 22 may include a metal material with excellent electrical conductivity.

[0051] The busbar assembly 100 according to an embodiment of the present invention 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.

[0052] Hereinafter, a busbar assembly according to one embodiment will be described with reference to FIGS.

[0053] FIG. 5 is a perspective view of a bus bar according to an embodiment.

[0054] Referring to FIG. 5, the busbar 200 guides electrical connections within the battery pack 1000 (see FIG. 2). The busbar 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 busbar 200 may include a copper (Cu) material. The body 210 may have a rod shape extending in one direction. In FIG. 2, the busbar 200 is shown as having a rod shape extending in a first direction DR1, for example.

[0055] In one embodiment, busbar 200 includes a main body portion 210 and end portions 220. Main body portion 210 may correspond to the center of busbar 200. End portions 220 extend from both ends of main body portion 210. For example, end portions 220 may extend from both ends of main body portion 210 in first direction DR1 and in the direction opposite to first direction DR1. For convenience, busbar 200 has been described herein as including main body portion 210 and end portions 220, but main body portion 210 and end portions 220 have an integral shape.

[0056] The end portion 220 is provided with through-holes HH. 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 portion 220 to connect the bus bar 200 to a terminal bus bar 22 (see FIG. 3) of a battery module 1200 (see FIG. 3).

[0057] FIG. 6 is a perspective view of a bus bar provided with an insulating layer according to one embodiment.

[0058] 6, the insulating layer 300 is provided to surround the main body 210 (see FIG. 5) of the bus bar 200. That is, the insulating layer 300 is provided to insulate the main body 210 (see FIG. 5). At this time, at least a portion of the end 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 refractory silicon. For example, the insulating layer 300 may be formed by molding refractory silicon on the outer peripheral surface of the body 210 (FIG. 5) of the bus bar 200. Unlike general silicone materials that burn when exposed to flames or high heat, refractory silicon can be ceramified at high heat. Therefore, when exposed to flames, refractory silicon ceramifies without burning, thereby maintaining the insulation properties of the bus bar 200. For example, refractory silicon can be ceramified at a temperature between 500°C and 1700°C. However, the temperature range at which refractory silicon ceramifies is not limited thereto.

[0060] The refractory silicone may contain 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 can serve as the base material for the refractory silicone material. For example, the silica may be fumed silica, a reinforcing filler contained in the silicone polymer. High-purity silicon chloride (SiCl4) compound can be produced from silicon metal as the main raw material through a reaction with hydrochloric acid and a purification process, and this can be reacted with hydrogen and oxygen in a high-temperature flame to produce fumed silica. The refractory silicone may also contain platinum (Pt) as a catalyst.

[0061] 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 ceramify and maintain its electrical insulation properties even when exposed to flame or in a high-heat environment, rather than burning or melting away.

[0062] Therefore, the insulating layer 300 insulates the main body 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.

[0063] A cap 400 (see FIG. 7 ), which will be described later, is connected to the insulating layer 300. In order to prevent the bus bar 200 from being exposed at the point where the insulating layer 300 and the cap 400 (see FIG. 7 ) are connected, the insulating layer 300 may extend to cover a portion of the end portion 220. In this case, both ends of the insulating layer 300 extend to a predetermined length without covering the through-hole HH of the end portion 220.

[0064] The insulating layer 300 may include a first portion 310 surrounding the main body portion 210 (see FIG. 5) of the bus bar 200 and a second portion 320 surrounding a part of the end portion 200.

[0065] First portion 310 may surround the outer peripheral surface of main body 210 of busbar 200. Second portion 320 extends from both ends of first portion 310 and is covered by cap 400, which will be described later. Second portion 320 may surround the top and side surfaces of end 220 of busbar 200. In other words, second portion 320 may not be disposed on the bottom surface of end 220. This is because cap 400, which will be described later, fits onto end 220 in a plane and surrounds the top and side surfaces of end 220 from the center.

[0066] The second portion 320 extends in opposite directions from both ends of the first portion 310. Specifically, the second portion 320 extends in the first direction DR1 from one end of the first portion 310 and in the opposite direction to the first direction DR1 from the other end of the first portion 310. The second portion 320 extends from the first portion 310 to an extent that it does not cover the through-hole HH of the end portion 220.

[0067] The insulating layer 300 includes a second portion 320, which can ensure an insulating distance. In addition, a cap 400 (see FIG. 7), which will be described later, surrounds the second portion 320, which can prevent the bus bar 200 from being exposed to the outside.

[0068] A recessed groove GV 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 on each end of the first portion 310. Because the groove GV has a recessed shape, an external fastener may be inserted into the groove GV.

[0069] Specifically, a cap 400 (see FIG. 7) described below may include a fastening portion that is inserted into the groove GV.

[0070] FIG. 7 is a plan view of a busbar assembly according to one embodiment.

[0071] 7 to 12, for ease of explanation, one end 220 of the bus bar 200 (see FIG. 6) is shown with a cap 400, and the other end 220 is shown without a cap 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 220 of the bus bar 200, as shown in FIG.

[0072] 7 , a bus bar assembly 100 according to one embodiment includes a bus bar 200, an insulating layer 300, and a cap 400. The insulating layer 300 insulates the main body 210 of the bus bar 200, and the cap 400 insulates the end 220 of the bus bar 200. The insulating layer 300 and the cap 400 are connected to each other; more specifically, the cap 400 is bonded to the insulating layer 300 while surrounding the second portion 320 of the insulating layer 300. This prevents the bus bar 200 from being exposed between the cap 400 and the insulating layer 300, ensuring an insulating distance.

[0073] Furthermore, a portion of the cap 400 is inserted into the groove GV of the insulating layer 300, and the cap 400 can be stably fixed to the insulating layer 300 without swinging from side to side.

[0074] The cap 400 may comprise a fire-resistant plastic, which may make the cap 400 harder and less resilient than the insulating layer 300, which comprises fire-resistant silicone.

[0075] In the present invention, since the insulating layer 300 has higher elasticity than the cap 400, the cap 400 can be fixed to the insulating layer 300 without a separate cap fixing tape. When the cap 400 tightly fits into the groove GV of the insulating layer 300, the insulating layer 300, which has a relatively high elasticity, is compressed and the cap 400 is inserted into the groove GV, and the elastic force of the insulating layer 300 fixes the cap 400 in the groove GV. This allows the conventional tape AL (see FIG. 1) for fixing the cap 400 to the insulating layer 300 to be omitted.

[0076] Furthermore, the cap 400 may include a fire-resistant plastic and exhibit excellent fire resistance. When exposed to a fire, the fire-resistant plastic can block the fire for a certain period of time without causing holes or tripping. Specifically, the fire-resistant plastic can protect the internal structure by forming a carbonized layer in the fire. The fire-resistant plastic may include at least one of a PPO (Polyphenylene Oxide)-based material, a PA (Polyamide)-based material, and a PBT (Polybutylene Terephthalate)-based material.

[0077] As a result, the bus bar assembly 100 of one embodiment has a simpler structure than conventional ones, and can have improved insulation properties and fire resistance.

[0078] The detailed structures of the insulating layer 300 and the cap 400 will be described with reference to FIG.

[0079] FIG. 8 is a side view of a busbar assembly according to one embodiment.

[0080] 8 , a cap 400 according to an embodiment may include a main body 410 and a fastening portion 420 extending from the main body 410. The fastening portion 420 extends from the end portion 220 of the bus bar 200 toward the main body 210 and is inserted into a groove GV formed in the insulating layer 300. In this case, the groove GV is formed within a protrusion 330 extending upward from the top surface of the first portion 310 of the insulating layer 300, thereby ensuring a sufficient depth. If the groove GV were formed directly on the top surface of the first portion 310 of the insulating layer 300 without the protrusion 330, the depth of the groove GV may be insufficient due to the main body 210 disposed inside the insulating layer 300.

[0081] As described above, when the fastening portion 420 of the cap 400 is tightly fitted into the groove GV, the high elasticity of the groove GV allows the fastening portion 420 to be inserted and fixed into the groove GV, thereby allowing the cap 400 to be stably connected to the insulating layer 300 without swinging left and right.

[0082] Furthermore, cap 400 may include fixing portion 430 extending downward from main body 410. Fixing portion 430 may cover at least a portion of the lower surface of busbar 200. Specifically, fixing portion 430 may cover at least a portion of the lower surface of end portion 220 of busbar 200. Cap 400 includes fixing portion 430, so that cap 400 can be stably fixed to busbar 200 without shaking up and down.

[0083] Meanwhile, the insulating layer 300 may be formed by injection molding the first portion 310, the second portion 320, and the protrusion 330 into a single integral shape.

[0084] A busbar assembly 100 according to one embodiment will now be described with reference to the cross-sectional views of Figures 9 to 12. Each of Figures 9 to 12 is a cross-sectional view of the busbar assembly according to one embodiment.

[0085] FIG. 9 is a cross-sectional view corresponding to the section line AA' shown in FIG.

[0086] 7 and 9, the main body 410 of the cap 400 surrounds and insulates the top and side surfaces of the end 220 of the bus bar 200. At this time, a space SP exists between the main body 410 and the end 220. Although not shown, the space SP is intended to accommodate an external fastening member (e.g., a bolt) inserted into the through-hole HH (see FIG. 7).

[0087] Fixing portion 430 extending downward from main body 410 covers the lower surface of end 220 of bus bar 200 .

[0088] The fixing portions 430 may be formed on one end and the other end of the end portion 220 in the first direction DR1. The fixing portions 430 allow the cap 400 to be fixed to the bus bar 200 without swinging up and down.

[0089] FIG. 10 is a cross-sectional view corresponding to the section line BB' shown in FIG.

[0090] 7 and 10, no fixing portion 430 is disposed below the end portion 220 corresponding to the cutting line B-B'. In other words, only the main body 410 surrounds and insulates the upper and side surfaces of the end portion 220. At this time, a space SP exists between the main body 410 and the end portion 220. Although not shown, the space SP is intended to accommodate an external fastening member (e.g., a bolt) inserted into the through-hole HH (see FIG. 7).

[0091] FIG. 11 is a cross-sectional view corresponding to the section line CC' shown in FIG.

[0092] 7 and 11, the second portion 320 of the insulating layer 300 is disposed on the end portion 220 of the bus bar 200, and the main body 410 of the cap 400 is disposed on the second portion 320.

[0093] The second portion 320 surrounds and insulates the side and top surfaces of the end portion 220. The body 410 may surround the second portion 320 without a separate space. The insulating layer 300 includes the second portion 320 overlapping the end portion 220, thereby ensuring an insulating distance.

[0094] FIG. 12 is a cross-sectional view corresponding to the section line DD' shown in FIG.

[0095] 7 and 12, the first portion 310 of the insulating layer 300 may surround the outer periphery of the body 210 of the bus bar 200. The first portion 310 may insulate the top, side, and bottom surfaces of the body 210. A protrusion 330 having a groove GV formed therein is located on the first portion 310. The fastening portion 420 of the cap 400 may be fastened to the groove GV.

[0096] FIG. 13 is a plan view of a busbar assembly according to one embodiment.

[0097] 13, the bus bar assembly 100 includes a bus bar 200, an insulating layer 300, and a cap 400. The cap 400 may include two caps 400a and 400b provided on both ends of the bus bar assembly 100. The two caps 400a and 400b may have shapes that are symmetrical with respect to the center of the bus bar assembly 100.

[0098] 7 to 13, in the busbar assembly 100 according to an embodiment, the fastening portion 420 of the cap 400 is fitted into the groove GV of the insulating layer 300, which has a relatively high elasticity, and can be stably fixed to the insulating layer 300 without swinging left and right. In addition, the fixing portion 430 of the cap 400 is disposed on the lower surface of the end 220 of the busbar 200, and can be stably fixed to the busbar 200 without swinging up and down.

[0099] FIG. 14 is a plan view of a busbar assembly according to one embodiment.

[0100] 14, the bus bar assembly 100 includes the bus bar 200, the insulating layer 300, and the cap 400, and may further include a glass fiber layer 500. The glass fiber layer 500 may be provided to surround the insulating layer 300 (see FIG. 13). The glass fiber layer 500 may provide physical protection for the internal structure. For example, the glass fiber layer 500 may prevent the insulating layer 300 (see FIG. 13) from being directly exposed to an external flame.

[0101] The glass fiber layer 500 may also provide structural rigidity to the bus bar assembly 100 and improve its insulating performance. If the insulating layer 300 (see FIG. 13) is ceramified in a fire or high-heat environment, the electrical insulation of the insulating layer 300 (see FIG. 13) can be maintained, but the strength of the insulating layer 300 (see FIG. 13) may be weakened and the insulating layer 300 (see FIG. 13) may be broken by an external force. The glass fiber layer 500 is provided to surround the insulating layer 300 (see FIG. 13) and can prevent the insulating layer 300 (see FIG. 13) from being broken by an external force.

[0102] In one embodiment, the glass fiber layer 500 may be provided in the form of a glass fiber tape and may be wound multiple times on the insulating layer 300 (see FIG. 13).

[0103] Meanwhile, the embodiment of the busbar assembly 100 of the present invention is not limited to the above.

[0104] FIG. 15 is a plan view of a busbar assembly according to one embodiment.

[0105] 15, a bus bar assembly 100-a according to one embodiment may include a bus bar 200, an insulating layer 300-a, and a cap 400-a. For ease of explanation, the bus bar 200 is shown as having a cap 400-a only on one end 220, with the other end 220 exposed and without a cap 400-a. However, this is for illustrative purposes only, and the bus bar assembly 100-a of the present invention may have a cap 400-a on each of both ends 220.

[0106] The outer peripheral surface of the bus bar 200 may be provided with an insulating layer 300-a.

[0107] The insulating layer 300-a may include a first portion 310 that surrounds the main body 210 (see FIG. 5) of the bus bar 200 and a second portion 320-a that surrounds a part of the end portion 200. The insulating layer 300-a may be formed by injection molding so that the first portion 310 and the second portion 320-a have an integral shape.

[0108] A recessed groove GV-a is formed in the insulating layer 300-a. In one embodiment, the groove GV-a may be formed along the periphery of the second portion 320-a and adjacent to the first portion 310. When the cap 400-a is provided on the end portion 220, at least a portion of the cap 400-a may be inserted into the groove GV-a of the second portion 320-a while covering the second portion 320-a. This prevents the cap 400-a from peeling off in the direction of the end portion 220. Two grooves GV-a may be provided, one formed in each of the two second portions 320-a.

[0109] FIG. 16 is a side view of a busbar assembly according to one embodiment.

[0110] 16 , first portion 310 may surround the outer peripheral surface of main body 210 of busbar 200. Second portion 320-a extends from both ends of first portion 310 and is covered by cap 400-a. Second portion 320-a may surround the upper and side surfaces of end 220 of busbar 200. In other words, second portion 320-a may not be disposed on the lower surface of end 220. This is because cap 400-a is fitted to end 220 in a plane and surrounds the upper and side surfaces of end 220.

[0111] The cap 400-a of one embodiment may include a main body 410 and a fixing portion 430 extending from a lower end of the main body 410. Unlike the cap 400 described above in FIG. 7, the cap 400-a of one embodiment does not include the fastening portion 420. This is because the cap 400-a can be stably connected to the insulating layer 300-a without including the fastening portion 420 by being inserted into the groove GV-a formed around the second portion 320-a.

[0112] The fixing portion 430 extends downward from the main body 410 and can cover at least a portion of the lower surface of the end portion 220 of the bus bar 200. The cap 400-a includes the fixing portion 430 and can be stably fixed to the bus bar 200 without shaking up and down.

[0113] FIG. 17 is a rear view of the bus bar assembly of one embodiment.

[0114] 16 and 17, the fixing portion 430 of the cap 400-a may be provided along at least a portion of the periphery of the end portion 220. Even if the cap 400-a does not include the fastening portion 420 (see FIG. 7), the fixing portion 430 is arranged along the periphery of the bus bar 200, so that sufficient fixing force can be ensured.

[0115] In the busbar assembly of the present invention, a relatively rigid cap is inserted into a relatively elastic insulating layer, and the elastic force of the insulating layer allows the cap to be bonded to the insulating layer. This eliminates the need for tape, which is conventionally used to secure the cap, and provides a busbar assembly with a simpler structure and improved insulation and fire resistance.

[0116] In the embodiments of the present invention, 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 vary depending on the position of the object of interest, the position of the observer, etc.

[0117] One or more battery modules according to the above-described embodiments of the present invention may be incorporated 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.

[0118] The battery module or battery pack can be applied to various devices, specifically, transportation means such as electric bicycles, electric cars, and hybrids, and energy storage systems (ESS), but is not limited thereto, and can be applied to various devices that can use secondary batteries.

[0119] 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 following claims also fall within the scope of the present invention. [Explanation of symbols]

[0120] 100, 100-a: Busbar assembly 200: Busbar 210: Main body 220:End 300, 300-a: insulating layer 310: Part 1 320, 320-a: 2nd part 330:Protrusion 400, 400-a: Cap 410:Main body 420: Fastening part 430: Fixed part 500: Glass fiber layer 1000: Battery pack 1100: Pack Frame 1200: Battery module 1300: BDU module 1400:BMS module

Claims

1. a bus bar including a main body portion and end portions extending from both ends of the main body portion and having through holes; an insulating layer surrounding the main body and having a recessed groove formed therein; a cap inserted into the groove and surrounding the end, The busbar assembly, wherein the insulating layer has a higher elasticity than the cap.

2. 2. The busbar assembly according to claim 1, wherein the insulating layer includes a first portion surrounding the body portion and a second portion extending from the first portion to surround a portion of the end portion and covered by the cap.

3. The busbar assembly according to claim 2 , wherein two of the grooves are provided on the upper surface of the first portion and are formed adjacent to the second portion.

4. The busbar assembly according to claim 3 , wherein the cap includes a fastening portion at least partially protruding toward the body portion and inserted into the groove.

5. the groove is formed along the periphery of the second portion; The busbar assembly of claim 2 , wherein the groove is adjacent to the first portion.

6. The busbar assembly according to claim 5 , wherein the cap is at least partially inserted into the groove while covering the second portion.

7. The busbar assembly according to claim 2 , wherein the first portion surrounds an outer circumferential surface of the busbar.

8. The busbar assembly according to claim 2 , wherein the second portion surrounds a top surface and a side surface of the busbar.

9. The busbar assembly according to claim 1 , wherein the cap covers at least a portion of a lower surface of the busbar.

10. The busbar assembly according to claim 1 , further comprising a glass fiber layer surrounding the insulating layer.

11. The busbar assembly according to claim 1 , wherein the insulating layer comprises silicon that ceramizes at high temperatures.

12. The busbar assembly of claim 1 , wherein the cap comprises a fire-resistant plastic.

13. At least one busbar assembly according to any one of claims 1 to 4; A battery module; a battery disconnect unit (BDU) module for controlling electrical connection of the battery modules; a BMS (Battery Management System) module that monitors and controls the operation of the battery module; 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.

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