Busbar assembly and battery pack containing it

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 document of said Korean patent application are incorporated herein by reference as part of the present specification.

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

[0003] In modern society, as the use of portable devices such as mobile phones, notebook computers, video cameras and digital cameras has become commonplace, development of technologies in the field related to such mobile devices has become active. In addition, rechargeable secondary batteries are used as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (P-HEVs) and the like as a solution to problems such as air pollution caused by existing gasoline vehicles using fossil fuels, so the need for development of secondary batteries is increasing.

[0004] Currently commercialized secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, lithium secondary batteries, etc. Among them, lithium secondary batteries have almost no memory effect compared to nickel-based secondary batteries, so charging and discharging are free. They are attracting attention because they have the advantages of extremely low self-discharge rate and high energy density.

[0005] Such lithium secondary batteries mainly use a lithium-based oxide and a carbon material as a positive electrode active material and a negative electrode active material, respectively. A lithium secondary battery comprises an electrode assembly in which a positive electrode plate and a negative electrode plate respectively coated with such a positive electrode active material and a negative electrode active material are disposed with a separator interposed therebetween, and a battery case that hermetically houses the electrode assembly together with an electrolyte.

[0006] Generally, lithium secondary batteries can be classified into two types based on the shape of their casing: can-type secondary batteries, in which the electrode assembly is housed in a metal can, and pouch-type secondary batteries, in which the electrode assembly is housed in an aluminum laminate sheet pouch.

[0007] In the case of secondary batteries used in small devices, two to three battery cells are arranged, but in the case of secondary batteries used in medium to large devices such as automobiles, a battery module is used in which many battery cells are electrically connected. In such battery modules, the capacity and output are improved by connecting many battery cells in series or parallel to each other to form a stack of battery cells. Furthermore, one or more battery modules can be incorporated together with various control and protection systems such as a BDU (Battery Disconnect Unit), a BMS (Battery Management System), and a cooling system to form a battery pack.

[0008] In battery packs, where numerous battery modules are assembled, the heat generated by the many battery cells can accumulate in a confined space, causing a rapid and excessive temperature increase. In other words, while high output can be obtained in battery modules with many stacked battery cells and battery packs in which these modules are attached, if the heat dissipation of the battery cells is not properly carried out, or if thermal runaway occurs in the battery cells, there is a high possibility of continuous ignition or explosion.

[0009] On the other hand, the battery pack is equipped with busbars that connect to the battery modules.

[0010] Figure 1 shows exploded perspective and assembled perspective views of a conventional busbar assembly.

[0011] Referring to Figure 1, a conventional busbar assembly 10 includes a busbar 20, a covering 20C surrounding the busbar 20, a cap CP, and tape AL for securing the cap CP. The busbar 20 is a rod-shaped metal member extending along its length. Through holes HH can be formed at both ends of the busbar 20 for connection to the terminal busbars of the battery module. Such a busbar 20 is configured to handle the HV (High Voltage) connection in the battery pack. HV connection refers to the connection of the power source for supplying power, and the busbar 20 is configured to guide the electrical connection of the battery module and is generally made of a metal material with excellent electrical conductivity. As an example, the busbar 20 may be made of copper (Cu).

[0012] The covering 20C may surround the busbar 20. The covering 20C may include an electrically insulating material, for example, silicone Alternatively, it may contain a material such as epoxy. Since the covering 20C surrounds the busbar 20 through which high current flows, it prevents the busbar 20 from coming into contact with other electrical components or conductive materials other than the terminal busbar of the battery module, thus preventing short circuits.

[0013] A fastening member is inserted into the through-hole HH of the busbar 20, allowing the busbar 20 to be connected to the terminal busbar of the battery module. For insulation, caps CP are attached to both ends of the busbar 20. The caps CP may be, for example, rubber caps. The caps CP may be attached to the covering 20C using tape AL.

[0014] Incidentally, when a flame is generated inside the battery pack, the flame is extremely hot, at approximately 1000°C, which can cause the covering 20C surrounding the busbar 20 to melt, or the cap CP and tape AL to melt, exposing the busbar 20. If the exposed busbar 20 comes into contact with other conductive materials and a short circuit occurs, the internal flame can spread further, potentially reaching the outside of the battery pack. Ultimately, this could lead to the explosion of the battery pack or the vehicle to which it is installed.

[0015] Therefore, there is a need for technological development of busbar assemblies that can maintain electrical insulation even if a flame occurs inside the battery pack. [Overview of the Initiative] [Problems that the invention aims to solve]

[0016] The problem that this invention aims to solve is to provide a busbar assembly and a battery pack containing the same that can maintain electrical insulation without melting even if a flame is generated inside the battery pack.

[0017] However, the problems that the embodiments of the present invention aim to solve are not limited to those described above, and can be broadly 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 with a main body and ends extending from both ends of the main body and having through holes, an insulating layer surrounding the main body and having recessed grooves formed therein, and a cap inserted into the grooves and surrounding the ends, wherein the insulating layer has higher elasticity than the cap.

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

[0020] The grooves may be provided in pairs on the upper surface of the first portion and formed adjacent to the second portion.

[0021] The cap may include a fastening portion that protrudes at least a portion in the direction of the main body and is inserted into the groove.

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

[0023] At least a part of the cap may be inserted into the groove while the cap covers the second portion.

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

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

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

[0027] The present invention may further comprise a glass fiber layer surrounding the insulating layer.

[0028] The insulating layer is ceramized at high temperature silicone and may comprise said material.

[0029] The cap may comprise a refractory plastic.

[0030] The battery pack of the present invention comprises at least one bus bar assembly, a battery module, a BDU (battery disconnect unit) module for controlling electrical connection of the battery module, and a BMS (Battery Management System) module for monitoring and controlling operation of the battery module, wherein the at least one bus bar assembly electrically connects at least one selected from between the battery modules, between the battery module and the BDU module, between the battery module and the BMS module, and between the BDU module and the BMS module.

Effect of the Invention

[0031] The bus bar assembly of the present invention enables the coating and the cap of the bus bar to maintain their shapes even in a fire, thereby improving insulating properties and fire resistance.

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

[0033] [Figure 1] These are exploded perspective and joined perspective views of a conventional busbar assembly. [Figure 2] This is a plan view of a battery pack according to one embodiment. [Figure 3] Figure 2 is a perspective view of one of the battery modules included in the battery pack. [Figure 4] Figure 3 is a partial perspective view showing the battery module with the module frame and end plate removed. [Figure 5] This is a perspective view of a busbar in one embodiment. [Figure 6] This is a plan view of a busbar equipped with an insulating layer according to one embodiment. [Figure 7] This is a plan view of a busbar assembly in one embodiment. [Figure 8] This is a side view of a busbar assembly in one embodiment. [Figure 9] This is a cross-sectional view of a busbar assembly according to one embodiment. [Figure 10] This is a cross-sectional view of a busbar assembly according to one embodiment. [Figure 11] This is a cross-sectional view of a busbar assembly according to one embodiment. [Figure 12] This is a cross-sectional view of a busbar assembly according to one embodiment. [Figure 13] This is a plan view of a busbar assembly in one embodiment. [Figure 14] This is a plan view of a busbar assembly in one embodiment. [Figure 15] This is a plan view of a busbar assembly in one embodiment. [Figure 16] This is a side view of a busbar assembly in one embodiment. [Figure 17] This is a rear view of a busbar assembly in one embodiment. [Modes for carrying out the invention]

[0034] The following describes various embodiments of the present invention in detail, with reference to the attached drawings, so that those with ordinary skill in the art to which the present invention pertains can easily implement them. The present invention can be realized in a variety of different forms and is not limited to the embodiments described herein.

[0035] To clearly explain the present invention, unnecessary explanatory parts have been omitted, and the same or similar reference numerals are used throughout the specification for identical or similar components.

[0036] Furthermore, the dimensions and thicknesses of each component shown in the drawings are arbitrary for the sake of explanation and are not necessarily limited to those shown in the present invention. In the drawings, the thicknesses are shown enlarged to clearly represent multiple layers and regions. Also, in the drawings, the thicknesses of some layers and regions are shown exaggerated for the sake of explanation.

[0037] Furthermore, when we say that a layer, membrane, region, plate, or other part is "on top of" or "on top of" another part, this includes not only the case where it is "directly on top of" the other part, but also the case where the other part is in between. When we say that one part is "directly on top of" another part, it means that there is no other part in between. Also, when we say that a part is "on top of" or "on top of" a reference part, it means that it is located above or below the reference part, and does not necessarily mean that it is located "on top of" or "on top of" in the opposite direction of gravity.

[0038] Furthermore, when a specification states that a certain part "includes" a certain component, unless otherwise stated, this means that it can further include other components rather than excluding them.

[0039] Furthermore, throughout the specification, "on a plane" refers to the view of the part in question from above, and "on a cross-section" refers to the view of the cross-section of the part in question, obtained by cutting it perpendicularly, 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 can intersect perpendicularly to each other. Throughout the specification, the concepts of up and down are described as being defined along the third direction DR3. Specifically, the upward or upper direction means the third direction DR3. The downward or lower direction means the opposite direction of the third direction DR3. In the specification, "thickness" means the length measured in the third direction DR3.

[0041] Figure 2 is a plan view of a battery pack according to one embodiment.

[0042] Referring to Figure 2, a battery pack 1000 according to one embodiment includes a busbar assembly 100, a pack frame 1100, battery modules 1200, a BDU (battery disconnect unit) module 1300 for controlling the electrical connections of the battery modules 1200, and a BMS (battery management system) module 1400 for monitoring and controlling the operation of the battery modules 1200. In an embodiment of the present invention, at least one busbar assembly 100 electrically connects at least one of the following: between battery modules 1200, between battery modules 1200 and BDU modules 1300, between battery modules 1200 and BMS modules 1400, and between BDU modules 1300 and BMS modules 1400. Specifically, multiple battery modules 1200 may be housed in the pack frame 1100, and the busbar assembly 100 can perform the electrical connections between the battery modules 1200 and between battery modules 1200 and BDU modules 1300. In other words, the busbar assembly 100 according to the embodiment of the present invention can handle HV (High Voltage) connections. Here, HV connection refers to a connection that acts as a power source for supplying power requiring high voltage, and means connections between battery cells or connections between battery modules.

[0043] On the other hand, the BDU module 1300 is a component for controlling the electrical connection of the battery module 1200, and can interrupt the power supply between the power converter and the battery module 1200. The BDU module 1300 can ensure the safety of the battery pack 1000 by interrupting the power supply to the battery pack 1000 when conditions occur in which the current exceeds a set range.

[0044] On the other hand, the LV connecting member 100' according to the embodiment of the present invention can be responsible for the electrical connection between the battery module 1200 and the BMS module 1400. Here, the electrical connection is an LV (Low voltage) connection, meaning a sensing connection for sensing and controlling the voltage and temperature of the battery module 1200. Specifically, sensors such as those inside the battery module 1200 are arranged, 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 state 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 the embodiment of the present invention can be responsible for the 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 Figures 3 and 4.

[0046] However, the battery module 1200 described below is an exemplary structure of a battery module including multiple battery cells 11, and various forms of battery modules including multiple battery cells can be applied.

[0047] Figure 3 is a perspective view showing one of the battery modules included in the battery pack shown in Figure 2.

[0048] Figure 4 is a partial perspective view showing the battery module from Figure 3 with the module frame and end plate removed.

[0049] Referring to Figures 3 and 4, the 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 Figure 4. Such a battery cell stack 11A may be housed in a module frame 30 and an end plate 40.

[0050] The battery cell 11 may be a pouch-type battery cell. Such a pouch-type battery cell may be formed by housing an electrode assembly in a pouch case made of a laminate sheet containing a resin layer and a metal layer, and then fusing the outer periphery of the pouch case. Such a battery cell 11 may be formed in a rectangular sheet structure. The electrode leads 11L connected to the electrode assembly protrude to the outside of the pouch case, but the electrode leads 11L of each battery cell 11 can be electrically connected to each other via a lead busbar 21. On the other hand, at least one electrode lead 11L can be connected to a terminal busbar 22. A portion of the terminal busbar 22 may be exposed to the outside of the battery module 1200, as shown in Figure 3. Both the lead busbar 21 and the terminal busbar 22 may contain a metal material with excellent electrical conductivity.

[0051] A busbar assembly 100 according to an embodiment of the present invention is electrically connected to such a terminal busbar 22, enabling the aforementioned HV connection. In other words, the battery module 1200 can be electrically connected to other battery modules 1200, BDU modules 1300, or BMS modules 1400 via the busbar assembly 100 connected to the terminal busbar 22.

[0052] A busbar assembly according to one embodiment will be described below with reference to Figures 5 to 12.

[0053] Figure 5 is a perspective view of a busbar in one embodiment.

[0054] Referring to Figure 5, the busbar 200 guides the electrical connections within the battery pack 1000 (see Figure 2). The busbar 200 is configured to guide the electrical connections, i.e., HV connections, of the battery module 1200 (see Figure 2), and may include a metal material with excellent electrical conductivity. For example, the busbar 200 may include copper (Cu) material. The main body 210 may have a rod shape extending in one direction. In Figure 2, as an example, the busbar 200 is shown to have a rod shape extending in the first direction DR1.

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

[0056] A through-hole HH is provided at the end portion 220. A fastening member is inserted into the through-hole HH, allowing the busbar 200 to be connected to an external electrical device. For example, a bolt can be inserted into the through-hole HH of the end portion 220 to connect the busbar 200 and the terminal busbar 22 (see Figure 3) of the battery module 1200 (see Figure 3).

[0057] Figure 6 is a perspective view of a busbar equipped with an insulating layer according to one embodiment.

[0058] Referring to Figure 6, the insulating layer 300 is provided so as to surround the main body 210 (see Figure 5) of the busbar 200. In other words, the insulating layer 300 is provided to insulate the main body 210 (see Figure 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 busbar 22 (see Figure 3) of the battery module 1200 (see Figure 3).

[0059] The insulating layer 300 is fire-resistant. silicone It may also include the following: For example, the main body portion 210 of the busbar 200, the outer surface shown in Figure 5, is fire-resistant. silicone By molding, an insulating layer 300 can be formed. Fire resistant silicone These are common things that are exposed to flames or burn at high temperatures. silicone Unlike the raw material, it can be ceramicized at high temperatures. Therefore, it is fire-resistant. silicone When exposed to flames, it can ceramicize without burning, maintaining its insulation properties to the busbar 200. For example, fire-resistant. silicone It can be ceramicized at temperatures between 500 degrees Celsius and 1700 degrees Celsius. However, fire resistance silicone The temperature range in which ceramicization occurs is not limited to this.

[0060] fireproof silicone teeth, silicone It may also contain polymers and silica. For example, silicone The polymer may be a polysiloxane-based compound having a vinyl group as a functional group, and is fire-resistant. silicone It can serve as a base material for other materials. For example, the silica to be applied is silicone A reinforcing filler contained in a polymer, which may be fumed silica. High-purity silicon chloride (SiCl4) compounds can be produced by reacting metallic silicon with hydrochloric acid and purifying them, and fumed silica can be obtained by reacting this with hydrogen and oxygen in a high-temperature flame. Also, fire resistance silicone It may also contain platinum (Pt) as a catalyst.

[0061] fireproof silicone When exposed to flames or high heat, silicone The decomposition of the polymer, along with the cross-linking of silica (SiO2), forms a ceramic material. siliconeAn insulating layer 300 in one embodiment, including the above, can maintain its electrical insulating properties by ceramicizing rather than burning or melting away when exposed to flames or placed in a high-temperature environment.

[0062] Therefore, the insulating layer 300 insulates the main body 210 (see Figure 5) of the busbar 200 even from flames and high temperatures, preventing the busbar 200 from coming into contact with other electrical components or conductive members and causing a short circuit.

[0063] A cap 400 (see Figure 7), described later, is connected to the insulating layer 300. To prevent the busbar 200 from being exposed at the point where the insulating layer 300 and the cap 400 (see Figure 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 Figure 5) of the busbar 200 and a second portion 320 surrounding a part of the end portion 200.

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

[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 direction of the first direction DR1 at one end of the first portion 310 and extends in the opposite direction of the first direction DR1 at the other end of the first portion 310. The second portion 320 extends from the first portion 310 to the extent that it does not cover the through hole HH of the end portion 220.

[0067] The insulating layer 300 includes the second portion 320, ensuring sufficient insulation distance. Furthermore, the cap 400 (see Figure 7), described later, surrounds the second portion 320, preventing the busbar 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 provided adjacent to the second portion 320. There may be two grooves GV, one at each end of the first portion 310. The recessed shape of the groove GV allows an external fastening part to be inserted into the groove GV.

[0069] Specifically, it may include a fastening portion into which a cap 400 (see Figure 7), described later, is inserted into the groove GV.

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

[0071] In the following drawings, Figures 7 to 12, for the sake of explanation, the busbar 200 is shown with a cap 400 attached to one end 220 (see Figure 6), while the other end 220 is not. However, this is for illustrative purposes only, and the busbar assembly 100 of the present invention includes caps 400 attached to both ends 220 of the busbar 200, as shown in Figure 13.

[0072] Referring to Figure 7, a busbar assembly 100 of one embodiment includes a busbar 200, an insulating layer 300, and a cap 400. The insulating layer 300 insulates the main body 210 of the busbar 200, and the cap 400 insulates the end 220 of the busbar 200. The insulating layer 300 and the cap 400 are connected to each other, specifically the cap 400 is coupled to the insulating layer 300 by surrounding the second portion 320 of the insulating layer 300. This prevents the busbar 200 from being exposed between the cap 400 and the insulating layer 300, and ensures sufficient insulation distance.

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

[0074] Cap 400 may contain fire-resistant plastic. This makes Cap 400 fire-resistant. silicone It may be harder and less elastic than the insulating layer 300 which contains [the specified material].

[0075] In this invention, the insulating layer 300 has higher elasticity than the cap 400, allowing the cap 400 to be fixed to the insulating layer 300 without the need for separate cap fixing tape. When the cap 400 is tightly fitted into the groove GV of the insulating layer 300, the relatively more elastic insulating layer 300 is compressed as the cap 400 is inserted into the groove GV, and the elastic force of the insulating layer 300 can fix the cap 400 within the groove GV. As a result, the conventional tape AL (see Figure 1) used to fix the cap 400 to the insulating layer 300 can be omitted.

[0076] Furthermore, Cap 400 can contain fire-resistant plastic and exhibit excellent fire resistance. Fire-resistant plastic can block flames without causing holes or tripping for a certain period of time when exposed to flames. Specifically, fire-resistant plastic can protect internal structures by forming a carbonized layer in the flame. Fire-resistant plastic may contain at least one of PPO (Polyphenylene Oxide)-based materials, PA (Polyamide)-based materials, and PBT (Polybutylene Terephthalate)-based materials.

[0077] As a result, the busbar assembly 100 of one embodiment has a simpler structure than conventional ones, and its insulation and fire resistance can be improved.

[0078] Referring to Figure 8, the detailed structure of the insulating layer 300 and the cap 400 will be described.

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

[0080] Referring to Figure 8, the cap 400 of one 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 220 of the busbar 200 toward the main body portion 210 and is inserted into a groove GV formed in the insulating layer 300. In this case, sufficient depth can be ensured by forming the groove GV within a projection 330 that extends upward from the upper surface of the first portion 310 of the insulating layer 300. If the groove GV were formed directly on the upper surface of the first portion 310 of the insulating layer 300 without the projection 330, the depth of the groove GV may not be sufficiently ensured by the main body portion 210 located inside the insulating layer 300.

[0081] As mentioned 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 into and fixed in the groove GV. As a result, the cap 400 can be stably connected to the insulating layer 300 without swaying from side to side.

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

[0083] On the other hand, the insulating layer 300 may be provided by injection molding the first portion 310, the second portion 320, and the protruding portion 330 into a single shape.

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

[0085] Figure 9 is a cross-sectional view corresponding to the cutting line A-A' shown in Figure 7.

[0086] Referring to Figures 7 and 9, the body 410 of the cap 400 surrounds and insulates the top and side surfaces of the end 220 of the busbar 200. At this time, a space SP exists between the body 410 and the end 220. Although not shown, the space SP is for accommodating an external fastening member (e.g., a bolt) inserted into the through hole HH (see Figure 7).

[0087] The fixing portion 430 extending downward from the main body 410 covers the lower surface of the end portion 220 of the busbar 200.

[0088] The fixing portion 430 may be formed on one end and the other end of the end portion 220 in the first direction DR1. The fixing portion 430 allows the cap 400 to be fixed to the busbar 200 without shaking up and down.

[0089] Figure 10 is a cross-sectional view corresponding to the cutting line B-B' shown in Figure 7.

[0090] Referring to Figures 7 and 10, the fixing portion 430 is not located at the bottom of the end portion 220 corresponding to the cutting line B-B'. In other words, only the main body 410 surrounds and insulates the top and sides 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 in the figures, the space SP is for accommodating an external fastening member (e.g., a bolt) inserted into the through hole HH (see Figure 7).

[0091] Figure 11 is a cross-sectional view corresponding to the cutting line C-C' shown in Figure 7.

[0092] Referring to Figures 7 and 11, the second portion 320 of the insulating layer 300 is placed on the end 220 of the busbar 200, and the body 410 of the cap 400 is placed on the second portion 320.

[0093] The second portion 320 insulates the sides and top of the end portion 220. The main body 410 can enclose the second portion 320 without any separate separation space. The insulating layer 300 includes the second portion 320 that overlaps the end portion 220, ensuring sufficient insulation distance.

[0094] Figure 12 is a cross-sectional view corresponding to the cutting line D-D' shown in Figure 7.

[0095] Referring to Figures 7 and 12, the first portion 310 of the insulating layer 300 can surround the outer circumferential surface of the main body portion 210 of the busbar 200. The first portion 310 can insulate the top, side, and bottom surfaces of the main body portion 210. A projection 330 with a groove GV formed inside is located on the first portion 310. The fastening portion 420 of the cap 400 may be fastened to the groove GV.

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

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

[0098] Referring to Figures 7 to 13 mentioned above, in one embodiment of the busbar assembly 100, the fastening portion 420 of the cap 400 is fitted into the groove GV of the relatively elastic insulating layer 300, allowing it to be stably fixed to the insulating layer 300 without swaying from side to side. In addition, the fixing portion 430 of the cap 400 is positioned on the lower surface of the end portion 220 of the busbar 200, allowing it to be stably fixed to the busbar 200 without swaying up and down.

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

[0100] Referring to Figure 14, the busbar assembly 100 includes a busbar 200, an insulating layer 300, and a cap 400, and may further include a fiberglass layer 500. The fiberglass layer 500 may be provided so as to surround the insulating layer 300 (see Figure 13). The fiberglass layer 500 may also provide physical protection for the internal structure. For example, the fiberglass layer 500 can prevent the insulating layer 300 (see Figure 13) from being directly exposed to an external flame.

[0101] Furthermore, the glass fiber layer 500 may also provide structural rigidity to the busbar assembly 100, thereby improving its insulation performance. When the insulating layer 300 (see Figure 13) becomes ceramic in a flame or high-temperature environment, the electrical insulation properties of the insulating layer 300 (see Figure 13) can be maintained, but the insulating layer 300 (see Figure 13) becomes weaker and may break due to external forces. The glass fiber layer 500 is provided so as to surround the insulating layer 300 (see Figure 13), which can prevent the insulating layer 300 (see Figure 13) from breaking due to external forces.

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

[0103] On the other hand, the embodiments of the busbar assembly 100 of the present invention are not limited to those described above.

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

[0105] Referring to Figure 15, the busbar assembly 100-a of one embodiment may include a busbar 200, an insulating layer 300-a, and a cap 400-a. For convenience of explanation, it is shown that the cap 400-a is provided only at one end 220 of the busbar 200, and the other end 220 is left exposed without a cap 400-a. However, this is for illustrative purposes only, and in the busbar assembly 100-a of the present invention, the cap 400-a may be provided at both ends 220, respectively.

[0106] An insulating layer 300-a may be provided on the outer surface of the busbar 200.

[0107] The insulating layer 300-a may include a first portion 310 surrounding the main body portion 210 (see Figure 5) of the busbar 200 and a second portion 320-a surrounding a part of the end portion 200. The insulating layer 300-a may be provided by injection molding such that the first portion 310 and the second portion 320-a have a single integrated 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 220, at least a portion of it 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 220. Two grooves GV-a may be provided, each formed in one of the two second portions 320-a.

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

[0110] Referring to Figure 16, the first portion 310 may surround the outer circumferential surface of the main body portion 210 of the busbar 200. The second portion 320-a extends from both ends of the first portion 310 and is covered by the cap 400-a. The second portion 320-a may surround the top and side surfaces of the end portion 220 of the busbar 200. In other words, the second portion 320-a may not be positioned on the bottom surface of the end portion 220. This is because the cap 400-a fits onto the end portion 220 on a plane and surrounds the top and side surfaces of the end portion 220.

[0111] In one embodiment, the cap 400-a may include a main body 410 and a fixing portion 430 extending from the lower end of the main body 410. Compared to the cap 400 described above in Figure 7, the cap 400-a in one embodiment does not include a fastening portion 420. This is because the cap 400-a can be stably connected to the insulating layer 300-a without including the aforementioned fastening portion 420 by being inserted into a 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 busbar 200. The cap 400-a includes the fixing portion 430 and can be stably fixed to the busbar 200 without shaking up and down.

[0113] Figure 17 is a rear view of a busbar assembly according to one embodiment.

[0114] Referring to both Figures 16 and 17, the fixing portion 430 of the cap 400-a may be provided along at least a portion of the end portion 220. Even without including the fastening portion 420 (see Figure 7), the cap 400-a can ensure sufficient fixing force because the fixing portion 430 is positioned along the busbar 200.

[0115] The busbar assembly of the present invention allows the cap to be bonded to the insulating layer by the elastic force of the insulating layer by inserting a relatively rigid cap into a relatively elastic insulating layer. This eliminates the need for tape conventionally used to secure the cap, resulting in a simpler structure and providing a busbar assembly with improved insulation and fire resistance.

[0116] In the embodiments of the present invention, terms indicating directions such as front, back, left, right, and up and down were used, but such terms are for explanatory convenience only and may change depending on the position of the object in question, the position of the observer, etc.

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

[0118] The aforementioned battery modules and battery packs can be applied to a variety of devices. Specifically, they can be applied to transportation methods such as electric bicycles, electric vehicles, and hybrids, as well as ESS (Energy Storage Systems), but are not limited to these and can be applied to a wide range of devices that can use secondary batteries.

[0119] Although preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto. Various modifications and improvements by those skilled in the art, using the basic concepts of the present invention as defined in the following claims, also fall within the scope of the present invention. [Explanation of Symbols]

[0120] 100, 100-a: Busbar assembly 200: Bus bar 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 unit 420: Fastening section 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 busbar including a main body and ends extending from both ends of the main body and having through holes, The aforementioned main body is surrounded by an insulating layer in which recessed grooves are formed, Includes a cap inserted into the groove and surrounding the end, The insulating layer is a busbar assembly having higher elasticity than the cap.

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

3. The busbar assembly according to claim 2, wherein two 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 that protrudes at least in the direction of the main body and is inserted into the groove.

5. The groove is formed along the periphery of the second portion, The groove is adjacent to the first portion, and is part of the busbar assembly according to any one of claims 2 to 4.

6. The busbar assembly according to claim 5, wherein the cap covers the second portion and at least a portion of it is inserted into the groove.

7. The first part is a busbar assembly according to any one of claims 2 to 4, which surrounds the outer circumferential surface of the busbar.

8. The second part is the busbar assembly according to any one of claims 2 to 4, which surrounds the top and side surfaces of the busbar.

9. The busbar assembly according to any one of claims 1 to 4, wherein the cap covers at least a portion of the lower surface of the busbar.

10. The busbar assembly according to any one of claims 1 to 4, further comprising a glass fiber layer surrounding the insulating layer.

11. The busbar assembly according to any one of claims 1 to 4, wherein the insulating layer contains silicone that ceramicizes at high temperatures.

12. The busbar assembly according to any one of claims 1 to 4, wherein the cap comprises fire-resistant plastic.

13. At least one busbar assembly according to any one of claims 1 to 4, Battery module and A BDU (battery disconnect unit) module for controlling the electrical connection of the battery module, The system includes a Battery Management System (BMS) module that monitors and controls the operation of the aforementioned battery module, A battery pack in which at least one busbar assembly electrically connects at least one of the following: between the battery modules, between the battery modules and the BDU module, between the battery modules and the BMS module, and between the BDU module and the BMS module.

Images