Highly heat-resistant battery pack connector and method of manufacturing same

Abstract

The present invention relates to a battery pack connector including a terminal pin which serves as an electrical connection path, a lower end to which the terminal pin is attached, a main body portion within which the lower end is disposed, and a housing including the lower end and the main body portion, wherein the terminal pin is attached to the lower end with an assembly portion including a highly moldable material added to a portion of its outer surface, and the housing is made of a highly heat-resistant material, and this prevents the battery pack connector from melting and prevents thermal runaway occurring inside the battery pack from diffusing to the outside.

Description

[Technical field]

[0001] This application claims the benefit of priority based on Korean Patent Application No. 10-2022-0064990 dated May 26, 2022, and all contents disclosed in the documents of that Korean patent application are incorporated herein by reference.

[0002] The present invention relates to a highly heat-resistant battery pack connector and a manufacturing method thereof, and more particularly to a highly heat-resistant battery pack connector that can improve the heat resistance of the battery pack connector, thereby increasing safety even at high heat and preventing thermal runaway, and a manufacturing method thereof. [Background technology]

[0003] Lithium secondary batteries have a problem in that if they catch fire, it is difficult to put out the pressure until the battery is completely burned. If thermal runaway occurs due to an abnormality in the battery cell, the connector next to the electrode lead is the first to be exposed to the flames.

[0004] The connector may cause secondary damage due to disconnection caused by flame or heat. A large number of battery cells can be bound together to be used as a battery module or a battery pack, and the connector is often a battery pack connector connected to a large number of battery cells. Conventional battery pack connectors are made of a material with low heat resistance and melt easily, so flames caused by thermal runaway may spread throughout the battery pack and may also spread quickly to the outside of the battery pack.

[0005] FIG. 1 is a perspective view of a conventional battery pack connection portion including a battery pack connector, FIG. 2 is a perspective view of only the battery pack connector of FIG. 1, and FIG. 3 is a cross-sectional view and a partially enlarged view of the dotted line in FIG.

[0006] 1 to 3, a battery pack connector 110 according to the prior art is located at one end of a battery pack 100.

[0007] Since the lower end of the battery pack connector 110 is electrically connected to the electrode terminal, the temperature increases rapidly in the event of a fire. Conventionally, the battery pack connector housing 200 was made of plastic, so the battery pack connector housing 200 could easily melt when the temperature of the battery pack increased.

[0008] However, the lower end 210 to which the terminal pin 240 is coupled must be molded with high precision due to the shape of the terminal pin 240, and therefore can only be manufactured by an injection molding method using plastic.

[0009] If the housing 200 of the battery pack connector 110 is made of a plastic with a low melting point, the melted portion is easily deformed or removed, forming an opening in the battery pack. Flames and sparks may be emitted through the opening in the battery pack. This may cause thermal runaway to be transmitted to other battery packs, which may cause a serious problem in the safety of the entire system including the battery packs.

[0010] In order to solve the above problems, various research efforts have been made.

[0011] Patent Document 1 relates to a battery module, which includes a connector exposed to the outside of the battery module for electrical connection with an external device, and the connector includes a metallic connector housing.

[0012] The technology disclosed in Patent Document 1 is configured so that static electricity flowing into a battery pack connector flows out to a ground pin connection part and a ground pin via an external metal housing of the connector, and the static electricity flowing to the ground pin is grounded via an external ground line. Patent Document 1 is a technology for solving problems caused by static electricity.

[0013] The '109 patent does not provide a method for solving the problem of the battery pack connector being damaged during a thermal runaway phenomenon.

[0014] Patent document 2 relates to a connector for a printed circuit board that includes a contact terminal having a contact pin at one end that contacts another connector and a terminal portion at the other end that contacts a printed circuit board, a housing in which the contact terminal is provided, and a hood for covering the contact pin of the contact terminal.

[0015] Patent Document 2 discloses a technology that enables the connector to be easily assembled and repaired and to be easily attached to a printed circuit board, but does not present a configuration for improving the heat resistance of the connector.

[0016] As described above, conventional battery pack connectors can melt and cause serious problems when thermal runaway occurs due to overheating, but no technology has been provided that recognizes or solves this problem. [Prior art documents] [Patent documents]

[0017] [Patent Document 1] Korean Patent Publication No. 10-2018-0090572 [Patent Document 2] Korean Patent No. 10-1136682 Summary of the Invention [Problem to be solved by the invention]

[0018] The present invention has been made to solve the above-mentioned problems, and aims to provide a highly heat-resistant battery pack connector and a manufacturing method thereof that can prevent the flame-vulnerable battery pack connector from melting and suppress the spread of thermal runaway when the temperature of the battery pack rises or a flame occurs inside the battery pack. [Means for solving the problem]

[0019] To achieve this objective, the connector for a battery pack according to the present invention includes a terminal pin which serves as an electrical connection path, a lower end to which the terminal pin is attached, a main body portion within which the lower end is disposed, and a housing including the lower end and the main body portion, wherein the terminal pin is attached to the lower end with an assembly portion including a highly moldable material added to a portion of its outer surface, and the housing can be made of a highly heat-resistant material.

[0020] The highly moldable material may be a thermoplastic resin that can be used for injection molding.

[0021] The highly moldable material may be an insulating material.

[0022] The high temperature resistant material may be ceramic or metal.

[0023] The high heat resistant material may be a material with a melting point of 1,000° C. or higher.

[0024] The lower end portion is formed with a plurality of through holes for connecting the terminal pin, and the exterior of an assembly part added to the outer surface of the terminal pin may have a shape corresponding to the inner shape of the plurality of through holes.

[0025] The terminal pin and the assembly may be of one-piece construction.

[0026] A partition for preventing deformation of the terminal pin when an external terminal is coupled to an upper portion of the lower end portion is formed, and the partition may be made of a highly heat-resistant material.

[0027] The present invention provides a method for manufacturing the battery pack connector, which may include the steps of: preparing a housing having a lower end formed with a plurality of through holes for coupling terminal pins, disposing the terminal pins in a mold and adding an injection material for forming an assembly part, and coupling the terminal pins to which the assembly parts, in which the injection material is solidified, are added, to the through holes.

[0028] The housing may be made of a high heat resistant material.

[0029] The assembly may be configured to encase the terminal pin.

[0030] The present invention also provides a method for manufacturing the battery pack connector, comprising the steps of: preparing a housing having a lower end formed with a plurality of through holes for coupling terminal pins thereto; injection molding an assembly part into the through holes of the housing; and coupling the terminal pins to the assembly part.

[0031] The housing may be made of a high heat resistant material.

[0032] The terminal pins may be coupled to the assembly by pressing them into place.

[0033] The present invention can also be provided in the form of various combinations of the above configurations. Effect of the Invention

[0034] As described above, the battery pack connector of the present invention has the lower end of the housing, except for the assembly part that is attached to the terminal pin, made of a highly heat-resistant material, so that the housing of the battery pack connector can be prevented from melting even in a high-temperature environment.

[0035] In this way, since most of the components of the housing, excluding the terminal pins and assembly parts, are made of highly heat-resistant materials, the shape of the housing of the battery pack connector can be maintained in a high-temperature environment, and even if a thermal runaway phenomenon occurs inside the battery pack, the thermal runaway can be prevented from spreading to the outside of the battery pack, thereby providing a battery pack with improved safety.

[0036] Furthermore, since an assembly portion made of a highly moldable material is added to terminal pins that are difficult to mold, the terminal pins can be stably attached.

[0037] The high heat resistant battery pack connector of the present invention can still maintain the high precision outer shape of conventional battery pack connectors. [Brief description of the drawings]

[0038] [Figure 1] 1 is a perspective view of a conventional battery pack connection including a battery pack connector; [Diagram 2] FIG. 2 is a perspective view of only the battery pack connector of FIG. [Diagram 3] 3 is a cross-sectional view and a partially enlarged view taken along the dotted line in FIG. 2. [Figure 4] 1 is a perspective view of a battery pack connector according to the present invention; [Diagram 5] 5 is a cross-sectional view of FIG. 4 with a terminal pin and an assembly portion omitted. [Figure 6] FIG. 6 is a cross-sectional view of FIG. 5 with the terminal pin and assembly added. [Figure 7] FIG. 5 is a bottom perspective view of the terminal pin before it is inserted in FIG. 4; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] Hereinafter, a detailed description will be given of an embodiment of the present invention that can be easily implemented by a person having ordinary skill in the art to which the present invention pertains, with reference to the accompanying drawings. However, when describing the operation principle of the preferred embodiment of the present invention in detail, detailed description of related well-known functions or configurations may be omitted if it is determined that such detailed description may unnecessarily obscure the gist of the present invention.

[0040] In addition, the same reference numerals are used throughout the drawings for parts having similar functions and actions. Throughout the specification, when a part is said to be connected to another part, this includes not only the case where the part is directly connected to another part, but also the case where the part is indirectly connected via another element between the two parts. In addition, when a part includes a certain component, it does not mean that the other component is excluded, but that the part may further include the other component, unless otherwise specified.

[0041] Furthermore, descriptions that limit or add specific elements are applicable to all inventions and are not limited to a particular invention unless otherwise specified.

[0042] Furthermore, throughout the description of the present invention and the claims, the singular includes the plural unless otherwise stated.

[0043] In addition, throughout the description of the present invention and the claims, unless otherwise stated, "or" includes "and." Therefore, "including A or B" means three cases: including A, including B, or including both A and B.

[0044] The invention will now be explained with reference to the drawings and in conjunction with detailed embodiments.

[0045] FIG. 4 is an oblique view of a battery pack connector according to the present invention, FIG. 5 is a cross-sectional view of FIG. 4 with the terminal pins and assembly portion omitted, and FIG. 6 is a cross-sectional view of FIG. 5 with the terminal pins and assembly portion added.

[0046] 4 to 6, the connector 1100 for a battery pack according to the present invention includes a terminal pin 1240 which serves as an electrical connection path, a lower end 1210 to which the terminal pin 1240 is attached, a body portion 1220 into which the lower end 1210 is disposed, and a housing 1200 including the lower end 1210 and the body portion 1220, the terminal pin 1240 being attached to the lower end 1210 with an assembly portion 1241 including a highly moldable material added to a portion of its outer surface, and the housing 1200 being made of a highly heat-resistant material.

[0047] That is, the battery pack connector 1100 according to the present invention includes terminal pins 1240 and an assembly part 1241 mounted in a housing 1200, and in this specification, the housing 1200 made of a highly heat-resistant material refers to the remaining parts excluding the terminal pins 1240 and the assembly part 1241.

[0048] The battery pack connector 1100 according to the present invention can be mounted on one end of the battery pack 100, similar to the battery pack 100 shown in FIG. 1, and is electrically connected to the terminals of the battery module inside the battery pack.

[0049] The connector for a battery pack according to the present invention may be a low-voltage connector that can be used to drive a battery management system or electrical components, or to sense the voltage and temperature of a battery cell.

[0050] If one of the battery cells inside the battery pack catches fire during use, the battery pack connector adjacent to the electrode lead is the first to be exposed to the flames.

[0051] If thermal runaway occurs in a battery cell, the surface temperature of the battery pack will exceed 600°C, and the temperature of the battery pack connector in contact with the battery pack will also increase rapidly. In order to prevent deformation of the battery pack connector and to prevent flames from erupting outside the battery pack, it is preferable that the battery pack connector be made of a material with a high melting temperature.

[0052] In the present invention, the housing of the battery pack connector is made of a highly heat-resistant material, so that even if the battery pack to which the battery pack connector is attached becomes hot, it does not easily melt and can stably maintain its shape.

[0053] However, since the terminal pin 1240 attached to the lower end 1210 has an elongated shape and a finely curved surface is formed on the outer surface, it is difficult to mold the assembly part 1241 added to the terminal pin 1240 and high precision is required during manufacturing. Therefore, the assembly part 1241 can be made of a plastic material with a lower melting point than the highly heat-resistant material constituting the housing, and can be manufactured by an injection molding method using a highly moldable material with excellent moldability.

[0054] In one embodiment, when using an insert injection molding method in which the terminal pin 1240 is placed in a mold beforehand and an injection material is injected to form the assembly 1241, the terminal pin 1240 and the assembly 1241 can have an integral structure.

[0055] The highly moldable material may be a thermoplastic resin that can be used in injection molding. Specifically, the thermoplastic resin may be at least one selected from the group including polyethylene (PE), polypropylene (PP), polystyrene (PS), acrylonitrile / butadiene / styrene (ABS) resin, polymethyl methacrylate (PMMA), polycarbonate (PC), polyoxymethylene (POM), polyamide (PA), polyphenylene oxide (PPO), polyphenylene ether (PPE), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), and polyvinyl chloride (PVC).

[0056] The highly formable material may be made of an insulating material such that it can be applied to the outer surface of the terminal pin 1240 to block electrical conductivity between the terminal pin 1240 and the lower end 1210 of the housing.

[0057] The insulating material is not particularly limited in type, but considering that the insulating material is manufactured by injection molding, the insulating material may be selected from the highly moldable materials.

[0058] The highly heat-resistant material is preferably a material that does not melt and maintains its shape even at high temperatures of 1,000° C. or more. For example, it may include ceramic and / or metal, and the metal may be stainless steel-based with a melting point of 1,000° C. or more. In addition, at least one of glass fiber reinforced plastics (GFRP), a recently developed highly heat-resistant material, processed materials made from mica, and ceramics made from inorganic materials may be used.

[0059] The high heat resistant material can be produced by adding a potting liquid and solidifying it, or by direct processing such as using a lathe or milling machine.

[0060] 5 and 6, a plurality of through holes 1211 for coupling with the terminal pins 1240 are formed in the lower end 1210, and the exterior of the assembly part 1241 added to the outer surface of the terminal pin 1240 may have a shape corresponding to the inner shape of the plurality of through holes 1211. Therefore, the assembly part 1241 may be stably and closely mounted in the through holes 1211.

[0061] A partition portion 1230 is formed on the upper part of the lower end portion 1210 as the part to which the external terminal is connected, to prevent deformation of the terminal pin 1240 when the external terminal is connected, and the partition portion 1230 is made of the same high heat resistant material as the lower end portion 1210 and the main body portion 1220.

[0062] In this manner, since the lower end, main body, and partition of the housing are made of a highly heat-resistant material, the housing can stably maintain its shape even when the temperature of the battery pack increases.

[0063] To manufacture the battery pack connector, the method may include the steps of preparing a housing having a lower end formed with a plurality of through holes for coupling terminal pins, placing the terminal pins in a mold and adding an injection material for forming an assembly part, and coupling the terminal pins to which the assembly parts in which the injection material has solidified have been added, to the through holes.

[0064] That is, the terminal pin is placed in a mold as an insert, and the mold is filled with an injection material, which is added to the insert, and then the injection material is cooled and solidified for a predetermined time. In this manner, an insert injection molded product is manufactured in which the assembly part made of the injection material and the terminal pin are integrated, and the assembly part is configured to completely enclose the terminal pin. When the terminal pin manufactured in this manner is inserted and installed in the through hole 1211 formed in the lower end part 1210 of the housing as shown in FIG. 5, it can become the shape shown in FIG. 6.

[0065] The housing is made of a highly heat-resistant material, and a potting liquid of the highly heat-resistant material is added to the mold, and then the potting liquid is solidified to produce a housing as shown in Fig. 5. Alternatively, the parts can be divided into smaller pieces and directly processed on a lathe or milling machine.

[0066] Another method for manufacturing the battery pack connector may include the steps of preparing a housing having a plurality of through holes formed at a lower end thereof for coupling to terminal pins, injection molding an assembly part into the through holes of the housing, and coupling the terminal pins to the assembly part.

[0067] FIG. 7 is a bottom perspective view of the terminal pin shown in FIG. 4 before it is inserted.

[0068] Referring to FIG. 7, an assembly portion 1241 is added to a through hole formed in a lower end portion 1210 of a housing body portion 1220, and a terminal pin 1240 is shown in an uncoupled state.

[0069] In other words, instead of performing insert injection molding on the terminal pins, the battery pack connector can be manufactured by adding an injected material to the through hole at the lower end 1210 of the housing to form the assembly part 1241, and then connecting the terminal pins 1240 to the assembly part 1241.

[0070] Alternatively, the assembly 1241 can be molded separately by adding injected material to a mold, and the assembly 1241 can be inserted into the through hole of the lower end 1210 of the housing, and then the terminal pin 1240 can be coupled to the assembly 1241 .

[0071] As a method for connecting the terminal pin to the assembly part, the terminal pin can be pressed into the assembly part to connect the terminal pin to the assembly part.

[0072] In the battery pack connector according to the present invention, the housing, excluding the terminal pins and assembly parts, is made of a highly heat-resistant material, so that the battery pack connector can be prevented from being damaged even if an explosion or fire occurs inside the battery pack.

[0073] Those skilled in the art will appreciate that various applications and modifications within the scope of the present invention will be possible based on the above content. [Explanation of symbols]

[0074] 100 Battery Packs 110, 1100 Battery pack connector 200, 1200 Housing 210, 1210 Lower end 1211 Through hole 1220 Main unit 1230 Bulkhead section 240, 1240 terminal pins 1241 Assembly Department

Claims

1. A terminal pin that serves as an electrical connection path; a lower end portion to which the terminal pin is attached; a main body portion having the lower end portion disposed therein; a housing including the lower end and the body portion; A battery pack connector comprising: The terminal pin is attached to the lower end with an assembly portion including a highly moldable material attached to a portion of an outer surface thereof, The housing is made of a high heat resistant material, a partition wall portion is formed on an upper portion of the lower end portion to prevent deformation of the terminal pin when an external terminal is coupled thereto.

2. 2. The battery pack connector according to claim 1, wherein the highly moldable material is a thermoplastic resin that can be used for injection molding.

3. 2. The battery pack connector according to claim 1, wherein the highly moldable material is an insulating material.

4. 2. The battery pack connector according to claim 1, wherein the high heat resistant material is a ceramic or a metal.

5. 2. The battery pack connector according to claim 1, wherein the high heat resistant material includes a material having a melting point of 1,000°C or higher.

6. The lower end portion is formed with a plurality of through holes for coupling the terminal pins, 2. The battery pack connector according to claim 1, wherein an outer appearance of an assembly portion added to an outer surface of said terminal pin has a shape corresponding to an inner shape of said plurality of through holes.

7. 2. The battery pack connector according to claim 1, wherein said terminal pin and said assembly portion are integrally formed.

8. A connector for a battery pack as described in claim 1, wherein the partition portion is made of a highly heat-resistant material.

9. A connector for a battery pack as described in claim 1, wherein the partition portion is spaced apart from the terminal pin.

10. A method for manufacturing the battery pack connector according to any one of claims 1 to 9, comprising the steps of: preparing the housing, the housing having a lower end formed with a plurality of through holes for coupling the terminal pins; placing the terminal pin in a mold and adding injected material to form the assembly; coupling the terminal pin having the assembly with the solidified injected material attached thereto to the through hole; A method for manufacturing a battery pack connector, comprising:

11. The method for manufacturing a battery pack connector according to claim 10, wherein the housing is made of a highly heat resistant material.

12. The method for manufacturing a battery pack connector according to claim 10 , wherein the assembly portion is configured to encase the terminal pin.

13. A method for manufacturing the battery pack connector according to any one of claims 1 to 9, comprising the steps of: preparing the housing, the housing having a lower end formed with a plurality of through holes for coupling the terminal pins; injection molding the assembly into the through hole of the housing; coupling the terminal pin to the assembly; A method for manufacturing a battery pack connector, comprising:

14. The method for manufacturing a battery pack connector according to claim 13, wherein the housing is made of a highly heat resistant material.

15. The method for manufacturing a battery pack connector according to claim 13, wherein the terminal pin is coupled to the assembly portion by a method of pushing the terminal pin into the assembly portion.

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