Busbar assembly and battery pack including same

Abstract

A busbar assembly, according to one embodiment of the present invention, comprises: a busbar connected, inside a battery pack, to a battery module so as to guide an electrical connection of the battery module; a first insulating layer surrounding the outer peripheral surface of the busbar and having respective recesses formed in both ends thereof; a second insulating layer surrounding the first insulating layer; and a cap comprising a main body which surrounds both ends of the busbar, and fixing parts which are inserted into the respective recesses.

Description

Busbar assembly and battery pack including the same

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority to Korean Patent Application No. 10-2023-0105717, filed August 11, 2023, the entire contents of which are incorporated herein by reference.

[0003] The present invention relates to a busbar assembly and a battery pack including the same, and more particularly, to a busbar assembly with improved insulation stability and a battery pack including the same.

[0004] In modern society, the widespread use of portable devices like cell phones, laptops, camcorders, and digital cameras has fueled active development of technologies related to these devices. Furthermore, rechargeable secondary batteries are increasingly being used as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (P-HEVs) to address air pollution caused by conventional gasoline-powered vehicles, further increasing the need for secondary battery development.

[0005] Currently commercialized secondary batteries include nickel cadmium batteries, nickel hydrogen batteries, nickel zinc batteries, and lithium secondary batteries. Among these, lithium secondary batteries are receiving attention for their advantages of being able to charge and discharge freely, having a very low self-discharge rate, and having a high energy density, as they have almost no memory effect compared to nickel-based secondary batteries.

[0006] These lithium secondary batteries primarily use lithium oxide and carbon materials as the positive and negative electrode active materials, respectively. The lithium secondary battery comprises an electrode assembly comprising a positive electrode plate and a negative electrode plate, each coated with the positive and negative electrode active materials, with a separator interposed between them, and a battery case that seals and houses the electrode assembly together with an electrolyte.

[0007] In general, lithium secondary batteries can be classified into can-type secondary batteries in which the electrode assembly is built into a metal can and pouch-type secondary batteries in which the electrode assembly is built into a pouch of an aluminum laminate sheet, depending on the shape of the outer packaging material.

[0008] Secondary batteries used in small devices are configured with two to three battery cells, but secondary batteries used in medium to large devices such as automobiles utilize battery modules in which multiple battery cells are electrically connected. These battery modules enhance capacity and output by forming a battery cell stack by connecting multiple battery cells in series or parallel. In addition, one or more battery modules may be mounted together with various control and protection systems, such as a Battery Disconnect Unit (BDU), a Battery Management System (BMS), and a cooling system, to form a battery pack.

[0009] Battery packs comprised of multiple battery modules can experience rapid and severe temperature increases due to the accumulation of heat from the numerous battery cells within a confined space. In other words, while battery modules stacked with multiple battery cells and battery packs equipped with these modules can achieve high output, if the heat dissipation between the cells is inadequate or if thermal runaway occurs, there is a high risk of continual fires or subsequent explosions.

[0010] Meanwhile, inside the battery pack, a bus bar is provided that connects to the battery module.

[0011] Figure 1 is an exploded perspective view and a combined perspective view of a conventional busbar assembly.

[0012] Referring to Fig. 1, a conventional busbar assembly (10) includes a busbar (20), a covering (20C) covering the busbar (20), a cap (CP), and a tape (AL) for fixing the cap (CP). The busbar (20) is a metal member in the shape of a rod extending along the longitudinal direction. A through hole (HH) for connection with a terminal busbar of a battery module may be formed at both ends of the busbar (20). This busbar (20) is a component that is responsible for the HV (High voltage) connection in a battery pack. The HV connection refers to a connection that serves as a power source for supplying electric power, and the busbar (20) is a component that guides the electrical connection of the battery module, and generally includes a metal material with excellent electrical conductivity. For example, the busbar (20) may include a copper (Cu) material.

[0013] The covering (20C) can wrap around the bus bar (20). The covering (20C) can include an electrically insulating material, for example, a material such as silicone or epoxy. Since the covering (20C) wraps around the bus bar (20) through which a high current flows, the bus bar (20) is prevented from coming into contact with other electrical components or conductive members other than the terminal bus bar of the battery module, thereby preventing a short circuit from occurring.

[0014] A fastening member is inserted into the through hole (HH) of the bus bar (20) to connect the bus bar (20) to the terminal bus bar of the battery module. For insulation, a cap (CP) is attached to both ends of the bus bar (20). The cap (CP) may be, for example, a rubber cap. The cap (CP) may be attached to the covering (20C) using a tape (AL).

[0015] However, when a flame occurs inside the battery pack, the temperature of the flame is very high, approximately 1000°C, so the covering (20C) surrounding the bus bar (20) may melt, or the cap (CP) and tape (AL) may melt, exposing the bus bar (20). If the exposed bus bar (20) comes into contact with another conductive member and a short circuit occurs, the internal flame may spread further and may even spread to the outside of the battery pack. Ultimately, this may lead to an explosion of the battery pack or a vehicle equipped with the battery pack.

[0016] Accordingly, there is a need for technology development for a busbar assembly that can maintain electrical insulation even when a flame occurs inside a battery pack.

[0017] The problem to be solved by the present invention is to provide a busbar assembly and a battery pack including the same that can maintain excellent electrical insulation even when a flame occurs inside the battery pack.

[0018] However, the problems to be solved by the embodiments of the present invention are not limited to the problems described above and can be expanded in various ways within the scope of the technical ideas included in the present invention.

[0019] The busbar assembly of the present invention comprises: a busbar connected to a battery module inside a battery pack to guide electrical connection of the battery module; a first insulating layer surrounding an outer circumferential surface of the busbar and having grooves formed at both ends; a second insulating layer surrounding the first insulating layer; and a cap including a main body surrounding both ends of the busbar and a fixing part inserted into the grooves.

[0020] In one embodiment, the thickness of the fixing portion is greater than the thickness of the first insulating layer, the lower portion of the fixing portion is coupled to the first insulating layer, and the upper portion of the fixing portion can be in contact with the second insulating layer.

[0021] In one embodiment, the second insulating layer may be disposed between the fixing members disposed at both ends of the bus bar.

[0022] In one embodiment, the thickness of the fixing portion is the same as the thickness of the first insulating layer, the fixing portion and the first insulating layer are located on the same layer, and the second insulating layer can be disposed on the fixing portion and the first insulating layer.

[0023] In one embodiment, a tape may be placed between the second insulating layer and the fixing member.

[0024] In one embodiment, the second insulating layer may have a tube shape comprising glass fibers.

[0025] In one embodiment, the outer surface of the second insulating layer may be coated with silicone.

[0026] In one embodiment, the second insulating layer may not include an adhesive material.

[0027] In one embodiment, the fixture may include a plurality of spaced apart protrusions, and the groove may include a plurality of spaced apart recesses into which the protrusions may be inserted.

[0028] In one embodiment, the fixing member comprises a shape of an extended block, and the groove may have a groove into which the block is inserted.

[0029] In one embodiment, the first insulating layer may comprise refractory silicone.

[0030] The battery pack of the present invention comprises 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 module and the BDU module, the battery module and the BMS module, and the BDU module and the BMS module.

[0031] The busbar assembly of the present invention minimizes the use of adhesive for bonding the cap and the insulating layer, thereby maintaining excellent insulation and fire resistance even when exposed to flame.

[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.

[0033] Figure 1 is an exploded perspective view and a combined perspective view of a conventional busbar assembly.

[0034] Figure 2 is a plan view of a battery pack of one embodiment.

[0035] FIG. 3 is a perspective view of one of the battery modules included in the battery pack of FIG. 2.

[0036] Fig. 4 is a partial perspective view showing the battery module of Fig. 3 with the module frame and end plate removed.

[0037] Figure 5 is a plan view of a busbar provided with an insulating layer according to one embodiment.

[0038] Figure 6 is a plan view of a cap of one embodiment.

[0039] Figure 7 is a plan view of a busbar provided with a cap and an insulating layer according to one embodiment.

[0040] Figure 8 is a plan view of a cap of one embodiment.

[0041] Figure 9 is a plan view of a busbar provided with a cap and an insulating layer according to one embodiment.

[0042] Fig. 10 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0043] Fig. 11 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0044] Fig. 12 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0045] Fig. 13 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0046] Figure 14 is a cross-sectional view of a busbar assembly of one embodiment.

[0047] Figure 15 is a cross-sectional view of a busbar assembly of one embodiment.

[0048] Fig. 16 is a cross-sectional view of a busbar assembly of one embodiment.

[0049] Hereinafter, various embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention. The present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0050] In order to clearly explain the present invention, parts that are not related to the description are omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0051] Furthermore, the sizes and thicknesses of each component shown in the drawings are arbitrarily indicated for convenience of explanation, and thus the present invention is not necessarily limited to the illustrated components. In the drawings, the thicknesses are enlarged to clearly represent various layers and regions. Furthermore, in the drawings, the thicknesses of some layers and regions are exaggerated for convenience of explanation.

[0052] Furthermore, when we say that a layer, membrane, region, plate, or other part is "on" or "over" another part, this includes not only cases where it is "directly on" the other part, but also cases where there are other parts in between. When we say that a part is "directly on" another part, we mean that there are no other parts in between. Furthermore, when we say that a part is "on" or "over" a reference part, we mean that it is located above or below the reference part, and we do not necessarily mean that it is located "above" or "over" the reference part in the opposite direction of gravity.

[0053] Additionally, throughout the specification, whenever a part is said to “include” a component, this does not mean that it excludes other components, but rather that it may include other components, unless otherwise specifically stated.

[0054] Additionally, throughout the specification, when we say "in plan", we mean when the target portion is viewed from above, and when we say "in cross section", we mean when the target portion is viewed from the side in a cross-section cut vertically.

[0055] Additionally, throughout the specification, the first direction (DR1), the second direction (DR2), and the third direction (DR3) are used as relative concepts. The first direction (DR1), the second direction (DR2), and the third direction (DR3) may be perpendicular to each other. Throughout the specification, the concept of up and down is explained as being distinguished along the third direction (DR3). Specifically, the upward or upper direction refers to the third direction (DR3). The downward or lower direction refers to the direction opposite to the third direction (DR3). The term “thickness” in the specification refers to the length measured in the third direction (DR3).

[0056] Figure 2 is a plan view of a battery pack of one embodiment.

[0057] Referring to FIG. 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 electrical connection of the battery modules (1200), and a BMS (battery management system) module (1400) for monitoring and controlling operation of the battery modules (1200). At least one busbar assembly (100) according to the present embodiment electrically connects at least one of the battery modules (1200), between the battery modules (1200) and the BDU module (1300), between the battery modules (1200) and the BMS module (1400), and between the BDU module (1300) and the BMS module (1400). Specifically, a plurality of battery modules (1200) can be housed in a pack frame (1100), and electrical connections between the battery modules (1200) or electrical connections between the battery modules (1200) and the BDU module (1300) can be made by the busbar assembly (100). That is, the busbar assembly (100) according to the present embodiment can be responsible for HV (High voltage) connections. Here, the HV connection is a connection that serves as a power source for supplying power requiring high voltage, and means a connection between battery cells or a connection between battery modules.

[0058] Meanwhile, the BDU module (1300) is a member for controlling the electrical connection of the battery module (1200) and can cut off power between the power conversion device and the battery module (1200). The BDU module (1300) can cut off power to the battery pack (1000) when a condition occurs in which the current exceeds a set range, thereby ensuring the safety of the battery pack (1000).

[0059] Meanwhile, the LV connecting member (100') according to the present embodiment can be responsible for the electrical connection between the battery module (1200) and the BMS module (1400). The electrical connection here is a LV (Low voltage) connection, which means a sensing connection for detecting and controlling the voltage and temperature of the battery module (1200). Specifically, sensors, etc. are arranged inside the battery module (1200), and real-time temperature information or 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 illustrated, there are cases where an HV current sensor is integrated into the BMS module (1400). In this case, the busbar assembly according to the present embodiment may be responsible for electrical connection between the battery module (1200) and the BMS module (1400) or between the BDU module (1300) and the BMS module (1400).

[0060] Referring to FIGS. 3 and 4, a battery module (1200) according to the present embodiment will be described. However, the battery module (1200) described below is an 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 may be applied.

[0061] FIG. 3 is a perspective view showing one of the battery modules included in the battery pack of FIG. 2.

[0062] Fig. 4 is a partial perspective view showing the battery module of Fig. 3 with the module frame and end plate removed.

[0063] Referring to FIGS. 3 and 4 together, the battery module (1200) according to the present embodiment may include a battery cell stack (11A) in which a plurality of battery cells (11) are stacked. The battery cell stack (11A) is illustrated in FIG. 4. This battery cell stack (11A) may be accommodated in a module frame (30) and an end plate (40).

[0064] The battery cell (11) may be a pouch-shaped battery cell. Such a pouch-shaped battery cell may be formed by housing 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. However, the battery cell (11) of the present invention is not limited to a pouch-shaped battery cell.

[0065] In one embodiment, the battery cell (11) may be formed in a rectangular sheet structure. The electrode lead (11L) connected to the electrode assembly protrudes to the outside of 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 illustrated in FIG. 3. Both the lead bus bar (21) and the terminal bus bar (22) may include a metal material having excellent electrical conductivity.

[0066] The busbar assembly (100) according to the present embodiment is electrically connected to the terminal busbar (22), so that the above-described HV connection can be made. That is, the battery module (1200) can be electrically connected to another battery module (1200), BDU module (1300), or BMS module (1400) via the busbar assembly (100) connected to the terminal busbar (22).

[0067]

[0068] Below, a busbar assembly according to one embodiment is described.

[0069] Figure 5 is a plan view of a busbar provided with an insulating layer according to one embodiment.

[0070] Referring to FIG. 5, a bus bar (200) guides electrical connections within a battery pack (1000, see FIG. 2). The bus bar (200) is configured to guide electrical connections, i.e., HV connections, of a battery module (1200, see FIG. 2), and may include a metal material having excellent electrical conductivity. For example, the bus bar (200) may include a copper (Cu) material. The bus bar (200) may have a rod shape extending in one direction. Through holes (HH) are defined at both ends of the bus bar (200). A fastening member may be inserted into the through hole (HH) to connect the bus bar (200) and a terminal bus bar (22, see FIG. 3) of the battery module (1200, see FIG. 3).

[0071] The first insulating layer (300) is provided to surround the bus bar (200). At this time, the through hole (HH) of the bus bar (200) is exposed from the first 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).

[0072] The first insulating layer (300) may include a refractory material. Specifically, the first insulating layer (300) may include refractory silicone. For example, the first insulating layer (300) may be formed by molding refractory silicone on the outer surface of the bus bar (200). Unlike typical silicone materials that burn when exposed to flame or at high temperatures, refractory silicone can be ceramized at high temperatures. Therefore, when exposed to flame, the refractory silicone does not burn but is ceramized, thereby maintaining insulation properties for the bus bar (200). For example, the refractory silicone can be ceramized at a temperature of 500 degrees Celsius or higher and 1700 degrees Celsius or lower. However, the temperature range at which the refractory silicone is ceramized is not limited thereto. The refractory silicone may include a silicone polymer and silica. For example, the applied silicone polymer may be a polysiloxane series compound having a vinyl group as a functional group, and may serve as a base material for a refractory silicone material. For example, the applied silica may be fumed silica as a reinforcing filler included in the silicone polymer. A high-purity silicon chloride (SiCl4) compound can be manufactured using metallic silicon as a main raw material through a reaction with hydrochloric acid and a purification process. Fumed silica can be obtained by reacting this with hydrogen and oxygen in a high-temperature flame. In addition, the refractory silicone may include platinum (Pt) as a catalyst.

[0073] When refractory silicone is exposed to flame or high temperature, the silicone polymer decomposes and silica (SiO2) is cross-linked to form a ceramic material. The first insulating layer (300) of one embodiment including refractory silicone can maintain electrical insulation properties by being ceramicized rather than burning or melting even when exposed to flame or high temperature. Therefore, the first insulating layer (300) can insulate the bus bar (200) without burning even in flame or high temperature, thereby preventing the bus bar (200) from contacting other electrical components or conductive members, thereby causing a short circuit.

[0074] A groove (GV) is formed at both ends of the first insulating layer (300). The groove (GV) has a shape that is sunken inward at both ends of the first insulating layer (300). In one embodiment, the groove (GV) may include a plurality of sunken portions spaced apart from each other. The groove (GV) is a structure for coupling with a cap (400) described below.

[0075] Figure 6 is a plan view of a cap of one embodiment.

[0076] Figure 7 is a plan view of a busbar provided with a cap and an insulating layer according to one embodiment.

[0077] Referring to FIGS. 6 and 7 together, the cap (400) covers both ends of the bus bar (200), and in particular, covers the through hole (HH). Although not illustrated, after the fastening member is inserted into the through hole (HH), the cap (400) covers both ends of the bus bar (200) and the fastening member. Therefore, the cap (400) has a space for storing the fastening member. In this drawing, for the convenience of explanation, the process of connecting the bus bar (200) to the terminal bus bar (22, see FIG. 3) by the fastening member is omitted. In addition, the cap (400) is bonded to the first insulating layer (300) to prevent the bus bar (200) from being exposed to the outside and to prevent a short circuit of the bus bar (200).

[0078] The cap (400) may include a refractory material. In one embodiment, the cap (400) may include any one of refractory plastic, mica, and refractory silicone. Accordingly, the cap (400) may exhibit excellent refractory properties.

[0079] When exposed to flame, refractory plastics can block flames for a certain period of time without forming holes or drips. Specifically, refractory plastics can protect internal structures by forming a carbonized layer in the flame. The refractory plastic may contain at least one of the following materials: polyphenylene oxide (PPO), polyamide (PA), and polybutylene terephthalate (PBT).

[0080] Mica has excellent fire resistance, heat resistance, high temperature resistance and electrical insulation properties, so it can act as a fire-resistant insulating layer without burning in flames or high temperatures.

[0081] For refractory silicone, the same content as described above for the first insulating layer (300) can be applied.

[0082] The cap (400) of the present invention includes a main body (410) and a fixing member (420). The main body (410) covers both ends of the bus bar (200) as described above and has a space for accommodating a fastening member. The fixing member (420) is inserted into a groove (GV) of the first insulating layer (300) so that the cap (400) is connected to the first insulating layer (300). The fixing member (420) may have a shape for being inserted into the groove (GV), and the fixing member (420) of one embodiment may include a plurality of protrusions spaced apart from each other. The fixing member (420) may be provided integrally with the main body (410), but the embodiment is not limited thereto. By coupling the fixing member (420) including a plurality of protrusions to the groove (GV) including a plurality of recessed portions, the bonding force between the cap (400) and the first insulating layer (300) may be strengthened.

[0083] Figure 8 is a plan view of a cap of one embodiment.

[0084] Figure 9 is a plan view of a busbar provided with a cap and an insulating layer according to one embodiment.

[0085] Referring to FIGS. 8 and 9 together, the cap (400-1) includes a main body (410) and a fixing portion (420-1), and the fixing portion (420-1) of one embodiment may include a single protrusion extending in one direction. The first insulating layer (300-1) of one embodiment may include a single recessed portion extending in one direction to match the shape of the fixing portion (420-1). Since the fixing portion (420-1) has a shape extending in one direction, the bonding area between the tape provided on the cap (400-1) and the cap (400-1) can be increased and the bonding strength can be enhanced.

[0086] Hereinafter, a busbar assembly (100) having the structure of the first insulating layer (300) and the cap (400) illustrated in FIGS. 6 and 7 will be described as an example. However, the following description can be equally applied to a busbar assembly having the structure of the first insulating layer (300-1) and the cap (400-1) illustrated in FIGS. 8 and 9.

[0087] Fig. 10 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0088] Fig. 11 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0089] Fig. 12 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0090] Fig. 13 is a plan view showing one step of a method for manufacturing a busbar assembly of one embodiment.

[0091] Referring to FIGS. 10 to 13, an example of a method for manufacturing a busbar assembly is described.

[0092] Referring to FIG. 10, a method for manufacturing a busbar assembly of one embodiment includes a step of providing a second insulating layer (500) on a first insulating layer (300). The second insulating layer (500) is provided to surround the first insulating layer (300). Specifically, after the cap (400) and the first insulating layer (300) are coupled at one end of the busbar (200), the second insulating layer (500) may be provided to surround the first insulating layer (300). The second insulating layer (500) may be provided in a tube shape. Specifically, the second insulating layer (500) provided in a tube shape may surround the first insulating layer (300) and be fitted in the longitudinal direction (Ld) of the busbar (200).

[0093] The second insulating layer (500) of the present invention may not include a separate adhesive material. The adhesive material may include, for example, at least one of epoxy resin, silicone resin, and acrylic resin. Since the second insulating layer (500) does not include an adhesive material, the generation of harmful gases from the adhesive material when a flame occurs can be prevented from deteriorating the insulation of the busbar assembly.

[0094] Referring to Fig. 11, after providing a second insulating layer (500) on a first insulating layer (300), a step of providing a cap (400) on the other end of the first insulating layer (300) is performed. As a fixing member (420) is inserted into a groove (GV) formed on the other end of the first insulating layer (300), the cap (400) is fixed to the other end of the first insulating layer (300).

[0095] Referring to Fig. 12, after the cap (400) is coupled to both ends of the bus bar (200, see Fig. 10), the second insulating layer (500) is spread so as to contact the fixing parts (420) at both ends. Instead of including an adhesive material, the second insulating layer (500) can be fixed by being sandwiched between the fixing parts (420) of the cap (400) at both ends. A detailed description thereof will be provided later with reference to Figs. 15 and 16.

[0096] Referring to FIGS. 12 and 13 together, a tape (600) may be provided on a fixing portion (420) to form a busbar assembly (100) of one embodiment. The tape (600) may be provided to cover the fixing portion (420) and a portion of the second insulating layer (500). The tape (600) may strengthen the bonding force between the cap (400) and the second insulating layer (500) and improve the insulation of the busbar assembly (100). The tape (600) may include, for example, a glass fiber layer. The glass fiber layer may physically protect the internal structure, and for example, the glass fiber layer may prevent the first insulating layer (300) from being directly exposed to an external flame. In a flame or high-temperature environment, when the first insulating layer (300) is ceramicized, the electrical insulation of the first insulating layer (300) may be maintained, but the strength may be weakened and the first insulating layer (300) may be broken by an external force. The glass fiber layer is provided to wrap the first insulating layer (300), thereby preventing the first insulating layer (300) from being broken by an external force. The busbar assembly (100) of one embodiment includes a tape (600) including a glass fiber layer, thereby improving structural rigidity and maintaining excellent insulation performance even in the event of a flame. Meanwhile, the tape (600) includes an adhesive layer in addition to the glass fiber layer to have adhesive properties. However, the tape (600) is used in a small amount, and the second insulating layer (500) that conventionally uses a glass fiber tape is replaced with a glass fiber tube that does not include an adhesive material, thereby minimizing the generation of harmful gases due to ignition of the adhesive material when the busbar assembly (100) is exposed to a flame.

[0097] Figure 14 is a cross-sectional view of a busbar assembly of one embodiment.

[0098] Fig. 14 is a cross-sectional view of an example of the busbar assembly (100) shown in Fig. 13, taken along line A-A'. Referring to Fig. 14, a first insulating layer (300) surrounds the outer surface of the busbar (200), and a second insulating layer (500) surrounds the outer surface of the first insulating layer (300).

[0099] In one embodiment, the second insulating layer (500) may include a glass fiber layer (510) and a coating layer (520). The glass fiber layer (510) may be the aforementioned glass fiber layer and may be provided in a tube shape without including a separate adhesive layer. The coating layer (520) may be formed by coating silicone on the outer surface of the glass fiber layer (510). The second insulating layer (500) may further improve fire resistance by including the coating layer (520).

[0100] Figure 15 is a cross-sectional view of a busbar assembly of one embodiment.

[0101] FIG. 15 is a cross-sectional view of one embodiment of the busbar assembly (100) illustrated in FIG. 13 taken along the line B-B'. Referring to FIG. 15, the thickness (H1) of the fixing portion (420) of the cap (400) may be greater than the thickness (T1) of the first insulating layer (300). Accordingly, when the fixing portion (420) is coupled to the first insulating layer (300), the first insulating layer (300) may contact the lower portion (PT1) of the fixing portion (420), and the remaining portion, the upper portion (PT2) of the fixing portion (420), may be exposed from the first insulating layer (300). The upper portion (PT2) of the fixing portion (420) may serve as a catch for fixing the second insulating layer (500). Specifically, the second insulating layer (500) is fixed by being sandwiched between the upper portions (PT2) of the fixing portions (420).

[0102] Referring to FIGS. 10 to 13 and FIG. 15 together, in FIGS. 10 and 11, the second insulating layer (500) is fitted so as to contact the upper portion (PT2) of the fixing portion (420) provided at one end. In FIG. 12, the second insulating layer (500) is fitted and fixed between the upper portions (PT2) of the fixing portions (420) provided at both ends. Therefore, even if the second insulating layer (500) does not include a separate adhesive material, the second insulating layer (500) can be stably fixed without moving in the longitudinal direction of the busbar (200) by the fixing portion (420) included in the cap (400). In addition, the tape (600) can improve the structural rigidity within the busbar assembly (100) by once again bonding the fixing portion (420) and the second insulating layer (500). The tape (600) may be omitted as needed.

[0103] Meanwhile, the embodiment of the cap (400) is not limited thereto.

[0104] Fig. 16 is a cross-sectional view of a busbar assembly of one embodiment.

[0105] FIG. 16 is a cross-sectional view of one embodiment of the busbar assembly (100) shown in FIG. 13 taken along the line B-B'. Referring to FIG. 16, in the cap (400-2) of one embodiment, the thickness (H2) of the fixing portion (420-2) may be the same as the thickness (T1) of the first insulating layer (300). Accordingly, when the fixing portion (420-2) is coupled to the first insulating layer (300), the first insulating layer (300) and the fixing portion (420-2) may be arranged on the same layer. In order to secure fixing force, a tape (600) may be provided to tape the cap (400-2) and the first insulating layer (300). Thereafter, a second insulating layer (500) may be provided to wrap the fixing portion (420-2), the tape (600), and the first insulating layer (300). Specifically, the second insulating layer (500) having a tube shape can be fitted so as to surround the outer surface of the tape (600) and the first insulating layer (300). Accordingly, the tape (600) is placed between the second insulating layer (600) and the fixing member (420). In the embodiment of FIG. 16, the second insulating layer (500) is placed and fixed between the main bodies (410) of the caps (400-2) provided at both ends. Meanwhile, the tape (600) may be omitted as needed.

[0106]

[0107] The busbar assembly of the present invention comprises a first insulating layer including a cap including a fixing portion and a groove into which the fixing portion can be inserted, thereby minimizing the amount of adhesive used to join the cap and the first insulating layer and preventing deterioration of insulation due to the generation of harmful gases from the adhesive during a flame. In addition, the second insulating layer disposed on the first insulating layer is provided in a tube shape that does not include an adhesive material, and the second insulating layer can be fixed by caps at both ends without an adhesive material. Accordingly, the busbar assembly of the present invention can maintain excellent insulation and fire resistance even when exposed to flame.

[0108]

[0109] In this example, terms indicating directions such as front, back, left, right, up, and down are used, but these terms are only for convenience of explanation and may vary depending on the location of the target object or the location of the observer.

[0110] One or more battery modules according to the above-described embodiment can be mounted together with various control and protection systems such as a BMS (Battery Management System), a BDU (Battery Disconnect Unit), and a cooling system to form a battery pack.

[0111] The above battery module or battery pack can be applied to various devices. Specifically, it can be applied to transportation vehicles such as electric bicycles, electric vehicles, and hybrid vehicles, as well as ESS (Energy Storage Systems), but is not limited thereto. It can also be applied to various devices that can use secondary batteries.

[0112] 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.

[0113] [Explanation of symbols]

[0114] 100: Busbar assembly

[0115] 200: Busbar

[0116] 300: First insulation layer

[0117] GV: Home

[0118] 400: Cap

[0119] 410: Body

[0120] 420: Fixed part

[0121] 500: Second insulation layer

[0122] 600: Tape

Claims

1. A bus bar that is connected to the battery module inside the battery pack and guides the electrical connection of the battery module; A first insulating layer that surrounds the outer surface of the above bus bar and has grooves formed at both ends; A second insulating layer surrounding the first insulating layer; and A busbar assembly comprising a body that surrounds both ends of the busbar and a cap that includes a fixing part that is inserted into the groove.

2. In paragraph 1, The thickness of the above fixed part is greater than the thickness of the first insulating layer, The lower part of the above fixed part is bonded to the first insulating layer, A busbar assembly in which a second insulating layer is in contact with the upper portion of the above-mentioned fixed part.

3. In paragraph 2, A busbar assembly in which the second insulating layer is disposed between the fixing members disposed at both ends of the busbar.

4. In paragraph 1, The thickness of the above fixed part is the same as the thickness of the first insulating layer, The above fixed part and the first insulating layer are located in the same layer, The second insulating layer is a busbar assembly disposed on the fixed portion and the first insulating layer.

5. In paragraph 4, A busbar assembly having a tape placed between the second insulating layer and the fixing member.

6. In paragraph 1, A busbar assembly having a tube shape including glass fibers, wherein the second insulating layer is 7. In paragraph 6, A busbar assembly having an outer surface of the second insulating layer coated with silicone.

8. In paragraph 1, A busbar assembly wherein the second insulating layer does not contain an adhesive material.

9. In paragraph 1, The above fixed part includes a plurality of protrusions spaced apart from each other, A busbar assembly wherein the above groove comprises a plurality of spaced recesses into which the above protrusions can be inserted.

10. In paragraph 1, The above fixed part comprises a shape of an extended block, The above home is a busbar assembly having a home into which the above block is inserted.

11. In paragraph 1, A busbar assembly wherein the first insulating layer comprises refractory silicone.

12. At least one busbar assembly according to paragraph 1; battery modules; A BDU (battery disconnect unit) module for controlling the electrical connection of the above battery modules; and Includes a BMS (Battery Management System) module that monitors and controls the operation of the above battery module, A battery pack wherein said at least one busbar assembly electrically connects at least one of 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.

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