Fuse-integrated busbar, battery pack including same and method for manufacturing fuse-integrated busbar

Abstract

The present invention provides a fuse-integrated busbar (30) comprising: a first busbar (32) formed by stacking a plurality of busbar layers (300) each including an element portion (310) including a melting portion (M) that melts when an overcurrent is applied thereto, and a first busbar portion (320) and a second busbar portion (330) integrally formed with the element portion (310) and extending from both longitudinal ends of the element portion (310) to both sides thereof, respectively; and an arc extinguishing member (34) that surrounds the plurality of element portions (310) of the plurality of busbar layers (300), and extinguishes an arc.

Description

Fuse-integrated busbar, battery pack including the same, and method for manufacturing the fuse-integrated busbar

[0001] This application claims the benefit of priority from Republic of Korea Patent Application No. 10-2023-0168410, dated November 28, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a fuse-integrated busbar, a battery pack including the same, and a method for manufacturing the fuse-integrated busbar. The present invention relates to a fuse-integrated busbar which can be easily manufactured with a simple configuration and low cost, has improved energy efficiency, quality, and quality uniformity, reliably blocks overcurrent, can be easily installed and maintained, has improved durability, can be miniaturized and lightened, and is suitable for short-circuit blocking in a battery module unit, and a battery pack including the same, and a method for manufacturing the fuse-integrated busbar.

[0003] Secondary batteries are widely used not only in portable devices but also in electric vehicles (EVs) or hybrid electric vehicles (HEVs) that are powered by electrical power sources.

[0004] Types of secondary batteries include lithium-ion batteries, lithium polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, and nickel-zinc batteries. The operating voltage of these unit secondary battery cells is approximately 2.5 V to 4.5 V.

[0005] Accordingly, in applications requiring high output voltages, such as vehicles, multiple battery cells are connected in series to form a battery pack. Furthermore, depending on the required charge / discharge capacity of the battery pack, multiple battery cells are connected in parallel to form a battery pack.

[0006] When configuring a battery pack by connecting multiple battery cells in series / parallel, multiple battery modules, each including multiple battery cells, may be configured first, and then a battery pack may be configured using the multiple battery modules.

[0007] Each battery module may be equipped with a fuse that cuts off the current of the battery module when overcurrent is applied to prevent accidents such as battery cell explosion. In other words, a fuse may be installed to prevent short circuits at the battery module level.

[0008] However, when fuses are installed to block short circuits at the battery module level, the number of fuses increases, which leads to problems such as increased manufacturing costs of the battery pack, increased energy loss and weight due to fuses, and wasted space. Furthermore, because short circuits were previously blocked at the battery pack level rather than the battery module level, there was a problem in that short circuits could not be quickly and accurately responded to, which lowered safety.

[0009] Therefore, a method is required to block short circuits at the battery module level while solving the above problem.

[0010] Prior art related to the present invention is Korean Patent No. 10-2379227.

[0011] The present invention has been devised to solve the above-described problems, and aims to provide a fuse-integrated bus bar and a battery pack including the same, which can reduce the number and types of parts and reduce manufacturing costs.

[0012] The purpose of the present invention is to provide a fuse-integrated busbar with improved energy efficiency, quality and quality uniformity, and a battery pack including the same.

[0013] The purpose of the present invention is to provide a fuse-integrated bus bar having improved durability as a fuse and a battery pack including the same.

[0014] The purpose of the present invention is to provide a fuse-integrated bus bar that can be easily installed and maintained, and a battery pack including the same.

[0015] The purpose of the present invention is to provide a fuse-integrated bus bar that reliably blocks overcurrent and a battery pack including the same.

[0016] The purpose of the present invention is to provide a fuse-integrated busbar that can easily improve the performance of a circuit breaker with a simple configuration and low cost, and a battery pack including the same.

[0017] The present invention aims to provide a fuse-integrated bus bar and a battery pack including the same, which can easily prevent the spread of arcs, flames or heat with a simple configuration and low cost, and can prevent damage caused by the spread of arcs, flames or heat.

[0018] The purpose of the present invention is to provide a fuse-integrated bus bar capable of preventing short circuits, fires, safety accidents, etc. due to external contact, and a battery pack including the same.

[0019] The purpose of the present invention is to provide a miniaturized and lightweight fuse-integrated bus bar and a battery pack including the same.

[0020] The purpose of the present invention is to provide a fuse-integrated busbar capable of easily manufacturing a fuse member with a simple configuration and low cost, and a battery pack including the same.

[0021] The present invention aims to provide a fuse-integrated busbar with improved energy efficiency, quality and durability, and a battery pack including the same.

[0022] The purpose of the present invention is to provide a fuse-integrated bus bar that easily blocks short circuits in battery module units with a simple configuration and low cost, and a battery pack including the same.

[0023] The purpose of the present invention is to provide a method for manufacturing a fuse-integrated busbar that can be easily manufactured with a simple configuration and low cost and has improved fuse performance.

[0024] The technical objectives of the present invention are not limited to the purposes mentioned above. Other objectives and advantages of the present invention not mentioned above can be understood through the following description and will be more clearly understood through the embodiments of the present invention. Furthermore, it will be readily apparent that the objectives and advantages of the present invention can be realized by the means and combinations thereof set forth in the claims.

[0025] To solve the above-described problem, the present invention provides a fuse-integrated bus bar including a first bus bar (32) and a fuse member (34).

[0026] The above first bus bar (32) can be formed by stacking multiple bus bar layers (300).

[0027] Each of the above plurality of busbar layers (300) may include an element portion (310), a first busbar portion (320), and a second busbar portion (330).

[0028] The above element portion (310) may include a melting portion (M) that melts when overcurrent is applied.

[0029] The above first bus bar section (320) and second bus bar section (330) can be formed integrally with the above element section (310).

[0030] The first bus bar portion (320) and the second bus bar portion (330) can be formed to extend to both sides from both longitudinal ends of the element portion (310).

[0031] The above-mentioned protective member (34) can wrap a plurality of the above-mentioned element parts (310) of the above-mentioned plurality of busbar layers (300).

[0032] The above-mentioned protective member (34) can extinguish an arc.

[0033] In one embodiment, the fuse-integrated busbar may further include a cover (36).

[0034] The above cover (36) can wrap the plurality of element parts (310) and the protective member (34).

[0035] In one embodiment, each of the above element portions (310) may include a hole (H).

[0036] The above hole (H) can be formed by penetrating the element portion (310) in the stacking direction.

[0037] The above hole (H) can define the above-mentioned cutting part (M).

[0038] The hole (H) of each of the above element parts (310) can be connected in the stacking direction with the hole (H) of the neighboring element part (310) in the stacking direction.

[0039] The above cover (36) may include an insertion portion (T).

[0040] The above insertion portion (T) can be inserted into the plurality of holes (H) of the plurality of element portions (310).

[0041] The protective member (34) may be interposed between the inner surface of the plurality of holes (H) and the outer surface of the insertion portion (T).

[0042] In one embodiment, the first bus bar portion (320), the second bus bar portion (330), and the element portion (310) of each of the bus bar layers (300) may be in contact with the first bus bar portion (320), the second bus bar portion (330), and the element portion (310) of the adjacent bus bar layers (300) in the stacking direction, respectively.

[0043] The plurality of the above-described cutting parts (M) of the plurality of the above-described element parts (310) can at least partially overlap each other in the length direction and width direction.

[0044] In one embodiment, the cutting portion (M) of each of the above element portions (310) can contact the cutting portion (M) of the neighboring element portion (310) in the stacking direction.

[0045] In one embodiment, the cutting section (M) of each of the above element sections (310) may include a first sub-cut section (MS1) and a second sub-cut section (MS2).

[0046] The first sub-end portion (MS1) and the second sub-end portion (MS2) can be spaced apart in the width direction with the hole (H) between them.

[0047] The above first sub-disconnection unit (MS1) and the second sub-disconnection unit (MS2) can be connected in parallel with each other.

[0048] In one embodiment, the first bus bar portion (320), the second bus bar portion (330), and the element portion (310) of each of the bus bar layers (300) may be in contact with the first bus bar portion (320), the second bus bar portion (330), and the element portion (310) of the adjacent bus bar layers (300) in the stacking direction, respectively.

[0049] The plurality of first sub-end portions (MS1) of the plurality of element portions (310) can at least partially overlap each other in the length direction and width direction.

[0050] The plurality of second sub-end portions (MS2) of the plurality of element portions (310) can at least partially overlap each other in the length direction and width direction.

[0051] In one embodiment, the width or thickness of the cutting portion (M) may be smaller than the width or thickness of adjacent portions on the outer sides of the longitudinal ends of the cutting portion (M).

[0052] Each of the above element parts (310) may include a plurality of the above cutting parts (M).

[0053] The above plurality of cutting sections (M) can be spaced apart from each other in the longitudinal direction.

[0054] The above plurality of cutting parts (M) can be connected to each other in series.

[0055] In one embodiment, the arc member (34) may expand when an arc occurs or the ambient temperature is higher than a predetermined temperature.

[0056] In one embodiment, the protective member (34) may be a foam formed by foaming a material including synthetic rubber.

[0057] In addition, to solve the above-described problem, the present invention provides a fuse-integrated bus bar including a second bus bar and a fuse member (34).

[0058] The above second bus bar may include an element portion (310), a first bus bar portion (320), and a second bus bar portion (330).

[0059] The above element portion (310) may include a melting portion (M) that melts when overcurrent is applied.

[0060] The above first bus bar section (320) and second bus bar section (330) can be formed integrally with the above element section (310).

[0061] The first bus bar portion (320) and the second bus bar portion (330) can be formed to extend from both ends of the longitudinal direction of the element portion (310) to both sides.

[0062] The above-mentioned protective member (34) can surround the element part (310) and extinguish the arc.

[0063] The above-mentioned protective member (34) may expand when an arc occurs or the ambient temperature is higher than a predetermined temperature.

[0064] The above-mentioned protective member (34) may be a foam formed by foaming a material including synthetic rubber.

[0065] In one embodiment, the synthetic rubber may comprise silicone rubber.

[0066] In addition, to solve the above-described problem, the present invention provides a battery pack including one or more battery modules (10); one or more connectors (20); and one or more fuse-integrated bus bars (30) according to any one of claims 1 to 12.

[0067] Each of the above one or more battery modules (10) may include one or more battery cells.

[0068] Each of the above one or more connectors (20) may be electrically connectable to an external device.

[0069] At least some of the one or more fuse-integrated bus bars (30) may be arranged between at least some of the one or more battery modules (10) and at least some of the one or more connectors (20) to directly electrically connect at least some of the battery modules (10) and at least some of the connectors (20), or may be arranged between two or more of the battery modules (10) to directly electrically connect the two or more battery modules (10) to each other.

[0070] In addition, to solve the above-described problem, the present invention provides a method for manufacturing a fuse-integrated bus bar, including a batching process (S510); a liquid injection process (S520); and a curing process (S530).

[0071] In the above arrangement process (S510), the element part (310) can be arranged inside the mold.

[0072] In the above injection process (S520), a foaming material including synthetic rubber can be injected into the mold and foamed.

[0073] In the above curing process (S530), the foaming material can be cured.

[0074] According to embodiments of the present invention, a fuse-integrated bus bar may include a first bus bar (32) and a fuse-extinguishing member (34). The first bus bar (32) may be formed by stacking a plurality of bus bar layers (300). Each of the plurality of bus bar layers (300) may include an element portion (310), a first bus bar portion (320), and a second bus bar portion (330). The element portion (310) may include a fusing portion (M) that is melted when an overcurrent is applied. The first bus bar portion (320) and the second bus bar portion (330) may be formed integrally with the element portion (310). The first bus bar portion (320) and the second bus bar portion (330) may be formed to extend to both sides from both longitudinal ends of the element portion (310), respectively. The above-mentioned arc-extinguishing member (34) can surround the plurality of element parts (310) of the plurality of busbar layers (300). The above-mentioned arc-extinguishing member (34) can extinguish an arc.

[0075] Accordingly, since the first busbar (32) has a fuse function, there is no need to manufacture or purchase a fuse separately, and there is no need to install a fuse between two busbars as in the past. Therefore, the number and types of parts can be reduced, and manufacturing costs can be reduced.

[0076] In addition, since the first / second busbar portions (320, 330) and the element portion (310) are formed integrally, energy efficiency, quality, and quality uniformity can be improved compared to the conventional case where a separate fuse is combined between the busbars. In addition, the thickness, width, and shape of the first / second busbar portions (320, 330) and the element portion (310) can be optimized so that resistance and heat generation are reduced when normal current is applied and reliably melted when overcurrent is applied.

[0077] In addition, since a plurality of busbar layers (300) are stacked to form the first busbar (32), the thickness of each busbar layer (300) can be reduced. Accordingly, since each busbar layer (300) can be easily deformed, even if force is applied to the fuse-integrated busbar (30), the melting portion (M) can be protected. For example, a compressive force or a tensile force applied to the busbar layer (300) (e.g., in the longitudinal direction) due to temperature change or impact, etc. can be relieved by deformation (e.g., bending or straightening) of a portion (e.g., the first busbar portion or the second busbar portion) other than the melting portion (M) of the busbar layer (300), so that the melting portion (M) can be protected. Accordingly, the durability of the fuse-integrated busbar (30) as a fuse can be improved.

[0078] In addition, since the thickness of each busbar layer (300) can be reduced, each busbar layer (300) can be easily deformed (e.g., bent) to suit the shape or position of the counterpart. At this time, each busbar layer (300) can be deformed and then fastened to the counterpart, or each busbar layer (300) can be deformed after being fastened to the counterpart. Accordingly, the fuse-integrated busbar (30) can be easily installed and maintained.

[0079] In addition, since the thickness of each busbar layer (300) can be reduced, the melting portion (M) of each busbar layer (300) can be reliably melted when overcurrent is applied. Accordingly, the fuse-integrated busbar (30) can reliably block overcurrent. In contrast, if the first busbar (32) is not composed of multiple layers and thus has a large thickness, the melting portion (M) may be incompletely melted when overcurrent is applied, resulting in failure to block overcurrent.

[0080] According to embodiments of the present invention, the fuse-integrated bus bar may further include a cover (36). The cover (36) may surround the plurality of element parts (310) and the extinguishing member (34).

[0081] Accordingly, the arc-protecting member (34) can be protected. In addition, since the state in which the arc-protecting member (34) surrounds the plurality of element parts (310) can be stably maintained by the cover (36), the arc-protecting performance of the fuse-integrated bus bar (30) can be improved.

[0082] According to embodiments of the present invention, each of the element portions (310) may include a hole (H). The hole (H) may be formed by penetrating the element portion (310) in the stacking direction. The hole (H) may define the cutting portion (M). The hole (H) of each of the element portions (310) may be connected in the stacking direction with the hole (H) of the neighboring element portion (310) in the stacking direction. The cover (36) may include an insertion portion (T). The insertion portion (T) may be inserted into a plurality of the holes (H) of the plurality of element portions (310). The arc-blocking member (34) may be interposed between the inner surface of the plurality of holes (H) and the outer surface of the insertion portion (T).

[0083] Accordingly, the arc-extinguishing member (34) can be brought into close contact with the inner surfaces of the plurality of holes (H) by the insertion portion (T) of the cover (36), and the close contact state can be stably maintained. Accordingly, the air (oxygen) inside the plurality of holes (H), i.e., the air (oxygen) around the cutting portion (M), can be reduced or eliminated. Therefore, the arc-extinguishing performance of the arc-extinguishing member (34) can be easily improved with a simple configuration and low cost.

[0084] According to embodiments of the present invention, the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of each of the bus bar layers (300) can be in contact with the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of the adjacent bus bar layers (300) in the stacking direction, respectively. The plurality of the cutting portions (M) of the plurality of element portions (310) can at least partially overlap each other in the length direction and the width direction.

[0085] Accordingly, even if the melting portion (M) of some busbar layers (300) is first broken due to temperature change, impact, or thermal energy, the heat generation, temperature, etc. of the fuse-integrated busbar (30) when normal current is applied may be similar to the case where the melting portion (M) is not broken. This is because the current that flowed through the first broken melting portion (M) can be distributed and flow through a plurality of melting portions (M) in the stacking direction that are very adjacent to the first broken melting portion (M). Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) can be improved.

[0086] In addition, since the fuse portion (M) can be supported or interfered with by an adjacent fuse portion (M) in the stacking direction, the fuse portion (M) is difficult to deform. Accordingly, the durability of the fuse-integrated bus bar (30) as a fuse can be improved.

[0087] In addition, the fuse-integrated bus bar (30) can uniformly and stably wrap the plurality of fuse-cutting sections (M) of the plurality of element sections (310). Accordingly, the fuse-integrated bus bar (30) can improve its fuse-integrated performance.

[0088] According to embodiments of the present invention, the cutting portion (M) of each of the above element portions (310) can be in contact with the cutting portion (M) of the neighboring element portion (310) in the stacking direction.

[0089] Accordingly, even if the melting portion (M) of some busbar layers (300) is first broken due to temperature change, impact, or thermal energy, the amount of heat generated, temperature, etc. of the fuse-integrated busbar (30) when normal current is applied may be similar to the case where the melting portion (M) is not broken. This is because the current that flowed through the first broken melting portion (M) can be distributed and flow through a plurality of melting portions (M) in the stacking direction that are very adjacent to and in contact with the first broken melting portion (M). Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) can be improved.

[0090] In addition, since the fuse portion (M) can be supported or interfered with by the fuse portion (M) that is in contact with the stacking direction, the fuse portion (M) is difficult to deform. Accordingly, the durability of the fuse-integrated bus bar (30) as a fuse can be improved.

[0091] In addition, air (oxygen) can be reduced or eliminated between a pair of adjacent welded portions (M) in the stacking direction. Accordingly, the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0092] According to embodiments of the present invention, the cutting part (M) of each of the element parts (310) may include a first sub-cutting part (MS1) and a second sub-cutting part (MS2). The first sub-cutting part (MS1) and the second sub-cutting part (MS2) may be spaced apart from each other in the width direction with the hole (H) therebetween. The first sub-cutting part (MS1) and the second sub-cutting part (MS2) may be connected in parallel to each other.

[0093] Accordingly, even if one of the first sub-fuse section (MS1) and the second sub-fuse section (MS2) of the fuse section (M) of each busbar layer (300) is first cut off due to temperature change, impact, or thermal energy, the normal current applied to each busbar layer (300) can flow through the other sub-fuse section. Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) can be improved.

[0094] According to embodiments of the present invention, the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of each of the bus bar layers (300) may be in contact with the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of the adjacent bus bar layers (300) in the stacking direction, respectively. The plurality of first sub-end portions (MS1) of the plurality of element portions (310) may at least partially overlap each other in the length direction and the width direction. The plurality of second sub-end portions (MS2) of the plurality of element portions (310) may at least partially overlap each other in the length direction and the width direction.

[0095] Accordingly, even if one of the sub-melting parts of some busbar layers (300) is first broken due to temperature change, impact, or thermal energy, the amount of heat generated, temperature, etc. of the fuse-integrated busbar (30) when normal current is applied may be similar to the case where the sub-melting part is not broken. This is because the current that flowed through one of the first broken sub-melting parts may flow through another sub-melting part adjacent in the width direction or may be distributed and flow through a plurality of sub-melting parts adjacent in the stacking direction. Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) may be improved.

[0096] In addition, since the sub-fuse section can be supported or interfered with by the adjacent sub-fuse section in the stacking direction, it is difficult for the sub-fuse section to be deformed. Accordingly, the durability of the fuse-integrated bus bar (30) as a fuse can be improved.

[0097] In addition, the arc-extinguishing member (34) can uniformly and stably wrap a plurality of first sub-end sections (MS1) and a plurality of second sub-end sections (MS2) of a plurality of element sections (310). Accordingly, the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0098] According to embodiments of the present invention, the width or thickness of the cutting portion (M) may be smaller than the width or thickness of adjacent portions on the outer sides of the longitudinal ends of the cutting portion (M). Each of the element portions (310) may include a plurality of the cutting portions (M). The plurality of cutting portions (M) may be spaced apart from each other in the longitudinal direction. The plurality of cutting portions (M) may be connected to each other in series.

[0099] Accordingly, at least one longitudinal melting portion (M) can be reliably melted. In particular, even if the sum total of the thicknesses of the melting portions (M) of the plurality of busbar layers (300) of the first busbar (32) is equal to the sum total of the thicknesses of the first busbar portion (320) or the second busbar portion (330) of the plurality of busbar layers (300), the melting portion (M) can be reliably melted when an overcurrent is applied. Therefore, the fuse-integrated busbar (30) can reliably block an overcurrent.

[0100] According to embodiments of the present invention, the arc-suppressing member (34) can expand when an arc occurs or the ambient temperature is higher than a predetermined temperature.

[0101] Accordingly, the spread of arcs, flames or heat can be easily prevented with a simple configuration and low cost, and damage caused by the spread of arcs, flames or heat can be prevented.

[0102] In addition, since external contact of the cutting part (M) is blocked by the expanded protective member (34), short circuit, fire, safety accidents, etc. can be prevented.

[0103] In addition, since the protective member (34) does not include a protective thread used in a conventional fuse, packaging or installation of the protective member (34) is easy, and the protective member (34) can be made smaller and lighter.

[0104] According to embodiments of the present invention, the protective member (34) may be a foam formed by foaming a material including synthetic rubber.

[0105] Accordingly, the arc-extinguishing member (34) can be brought into close contact with the element portion (310) by the foaming pressure applied when the synthetic rubber foam is formed, so that the air (oxygen) around the element portion (310) can be reduced or eliminated. Accordingly, the arc-extinguishing member (34) can be easily manufactured with a simple configuration and low cost, and the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0106] In addition, synthetic rubber generally has excellent elasticity and heat resistance, so the protective member (34) can stably expand while absorbing heat energy. Accordingly, the spread of arcs, flames, or heat can be stably blocked with a simple configuration and low cost.

[0107] In addition, since synthetic rubber foam is used instead of the protective material of a conventional fuse, packaging or installation of the protective material (34) is easy, and the protective material (34) can be made smaller and lighter.

[0108] According to embodiments of the present invention, a fuse-integrated bus bar may include a second bus bar and an arc-extinguishing member (34). The second bus bar may include an element portion (310), a first bus bar portion (320), and a second bus bar portion (330). The element portion (310) may include a fusing portion (M) that is melted when an overcurrent is applied. The first bus bar portion (320) and the second bus bar portion (330) may be formed integrally with the element portion (310). The first bus bar portion (320) and the second bus bar portion (330) may be formed to extend in both directions from both longitudinal ends of the element portion (310), respectively. The arc-extinguishing member (34) may surround the element portion (310) and extinguish an arc. The above-mentioned protective member (34) can expand when an arc occurs or the ambient temperature is higher than a predetermined temperature. The above-mentioned protective member (34) can be a foam formed by foaming a material including synthetic rubber.

[0109] Accordingly, since the second busbar functions as a fuse, there is no need to manufacture or purchase a separate fuse, nor is there a need to install a fuse between the two busbars as was done previously. This reduces the number and type of parts, thereby lowering manufacturing costs.

[0110] In addition, since the first / second busbar portions (320, 330) and the element portion (310) are formed integrally, energy efficiency, quality, and quality uniformity can be improved compared to the conventional case where a separate fuse is combined between the busbars. In addition, the thickness, width, and shape of the first / second busbar portions (320, 330) and the element portion (310) can be optimized so that resistance and heat generation are reduced when normal current is applied and reliably melted when overcurrent is applied.

[0111] In addition, it can easily block the spread of arcs, flames or heat with a simple configuration and low cost, and prevent damage caused by the spread of arcs, flames or heat.

[0112] In addition, since external contact of the cutting part (M) is blocked by the expanded protective member (34), short circuit, fire, safety accidents, etc. can be prevented.

[0113] In addition, since the protective member (34) does not include a protective thread used in a conventional fuse, packaging or installation of the protective member (34) is easy, and the protective member (34) can be made smaller and lighter.

[0114] In addition, since the arc-extinguishing member (34) can be brought into close contact with the element portion (310) by the foaming pressure when the synthetic rubber foam is formed, the air (oxygen) around the element portion (310) can be reduced or eliminated. Accordingly, the arc-extinguishing member (34) can be easily manufactured with a simple configuration and low cost, and the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0115] In addition, synthetic rubber generally has excellent elasticity and heat resistance, so the protective member (34) can stably expand while absorbing heat energy. Accordingly, the spread of arcs, flames, or heat can be stably blocked with a simple configuration and low cost.

[0116] In addition, since synthetic rubber foam is used instead of the protective material of a conventional fuse, packaging or installation of the protective material (34) is easy, and the protective material (34) can be made smaller and lighter.

[0117] According to embodiments of the present invention, the synthetic rubber may include silicone rubber.

[0118] Accordingly, silicone rubber foam can stably expand while absorbing heat energy. This is because silicone rubber foam has excellent elasticity and heat resistance. Therefore, it can reliably prevent the spread of arcs, flames, or heat with a simple configuration and low cost.

[0119] According to embodiments of the present invention, a battery pack may include one or more battery modules (10); one or more connectors (20); and one or more fuse-integrated bus bars (30) according to any one of claims 1 to 12. Each of the one or more battery modules (10) may include one or more battery cells. Each of the one or more connectors (20) may be electrically connectable to an external device. At least some of the one or more fuse-integrated bus bars (30) may be arranged between at least some of the one or more battery modules (10) and at least some of the one or more connectors (20) to directly electrically connect at least some of the battery modules (10) and at least some of the connectors (20), or may be arranged between two or more of the battery modules (10) to directly electrically connect the two or more battery modules (10) to each other.

[0120] Accordingly, short circuits can be easily blocked in battery module (10) units with a simple configuration and low cost. Accordingly, the safety of the battery pack (1) can be improved.

[0121] According to embodiments of the present invention, a method for manufacturing a fuse-integrated busbar may include a placement process (S510); a pouring process (S520); and a curing process (S530). In the placement process (S510), the element portion (310) may be placed inside a mold. In the pouring process (S520), a foaming material including synthetic rubber may be poured into the mold and foamed. In the curing process (S530), the foaming material may be cured.

[0122] Accordingly, the arc-extinguishing member (34) of the fuse-integrated bus bar (30) can be easily manufactured with a simple configuration and low cost. In addition, the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved. This is because the arc-extinguishing member (34) can be formed in close contact with the element portion (310) by the foaming pressure applied when the synthetic rubber foam is formed, so that the air (oxygen) around the element portion (310) can be reduced or eliminated.

[0123] In addition to the effects described above, specific effects of the present invention are described below while explaining specific details for carrying out the invention.

[0124] FIG. 1 is a perspective view schematically illustrating a battery pack according to one embodiment of the present invention.

[0125] Figures 2 to 5 are perspective views and exploded perspective views showing the fuse-integrated bus bar of the battery pack of Figure 1.

[0126] Fig. 6 is a perspective view showing the first bus bar of the fuse-integrated bus bar of Figs. 2 to 5.

[0127] Figures 7 and 8 are a perspective view and a partial plan view showing the busbar layer of the first busbar of Figure 6.

[0128] Fig. 9 is a flowchart showing a method for manufacturing a fuse-integrated bus bar according to one embodiment of the present invention.

[0129] [Explanation of symbols]

[0130] 1: Battery pack

[0131] 10: Battery module 20: Connector

[0132] 30: Fuse integrated busbar 32: First busbar

[0133] 300: Busbar layer 310: Element section

[0134] M: Hall M1: First Hall

[0135] M2: 2nd hole M3: 3rd hole

[0136] MS1: 1st sub-hole MS2: 2nd sub-hole

[0137] G: Home

[0138] 320: Bus 1, Bus 2, Bus 330: Bus 2

[0139] 34: Absence of Soho

[0140] H': Hole G': Home

[0141] 36: Cover

[0142] T: Insertion P: Protrusion

[0143] The above-described objects, features, and advantages will be described in detail below with reference to the accompanying drawings, so that those skilled in the art can easily practice the technical idea of ​​the present invention. In describing the present invention, if it is determined that a detailed description of known technologies related to the present invention may unnecessarily obscure the gist of the present invention, a detailed description thereof will be omitted. Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used to indicate the same or similar components.

[0144] Although terms like "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are used merely to distinguish one component from another, and unless otherwise specified, a "first" component may also be a "second" component.

[0145] Throughout the specification, unless otherwise specifically stated, each element may be singular or plural.

[0146] Hereinafter, the phrase "any configuration is placed on (or below)" a component or "on (or below)" a component may mean that any configuration is placed in contact with the upper surface (or lower surface) of said component, and that other configurations may be interposed between said component and any configuration placed on (or below) said component.

[0147] Additionally, when it is described that a component is "connected," "coupled," or "connected" to another component, it should be understood that the components may be directly connected or connected to one another, but that other components may also be "interposed" between the components, or that each component may be "connected," "coupled," or "connected" through another component.

[0148] As used herein, singular expressions include plural expressions unless the context clearly dictates otherwise. In this application, terms such as "consisting of" or "comprising" should not necessarily be construed to include all of the components or steps described in the specification, and should be construed to mean that some of the components or steps may not be included, or that additional components or steps may be included.

[0149]

[0150] FIG. 1 is a perspective view schematically illustrating a battery pack according to one embodiment of the present invention. FIGS. 2 to 5 are perspective views and exploded perspective views illustrating a fuse-integrated busbar of the battery pack of FIG. 1. FIG. 6 is a perspective view illustrating a first busbar of the fuse-integrated busbar of FIGS. 2 to 5. FIGS. 7 and 8 are perspective views and partial plan views illustrating a busbar layer of the first busbar of FIG. 6. FIG. 9 is a flowchart illustrating a method for manufacturing a fuse-integrated busbar according to one embodiment of the present invention.

[0151]

[0152] [Battery pack]

[0153] Referring to FIG. 1, a battery pack (1) may include one or more battery modules (10), one or more connectors (20), and one or more fuse-integrated bus bars (30).

[0154] Each of one or more battery modules (10) may include one or more battery cells.

[0155] One or more connectors (20) may each be electrically connectable to an external device. Here, the external device may be a power supply device (e.g., a charger) or a power consumption device (e.g., a motor).

[0156] At least some of the one or more fuse-integrated bus bars (30) can be arranged between at least some of the one or more battery modules (10) and at least some of the one or more connectors (20). Accordingly, at least some of the one or more fuse-integrated bus bars (30) can directly electrically connect at least some of the battery modules (10) and at least some of the connectors (20).

[0157] At least some of the one or more fuse-integrated bus bars (30) can be placed between two or more battery modules (10). Accordingly, at least some of the one or more fuse-integrated bus bars (30) can directly electrically connect the two or more battery modules (10) to each other.

[0158] Accordingly, short circuits can be easily blocked in battery module (10) units with a simple configuration and low cost. Accordingly, the safety of the battery pack (1) can be improved.

[0159] Below, we will look at the fuse-integrated bus bar (30).

[0160]

[0161] [First embodiment of a fuse-integrated busbar]

[0162] Referring to FIGS. 2 to 5, the fuse-integrated busbar (30) according to the first embodiment may include a first busbar (32) and a fuse-protecting member (34). The fuse-integrated busbar (30) according to the first embodiment may further include a cover (36).

[0163]

[0164] [Bus Bar No. 1]

[0165] Referring further to FIGS. 6 to 8, the first bus bar (32) can be formed by stacking a plurality of bus bar layers (300).

[0166] The thickness of the busbar layer (300) may be less than 1 / 10 of the width of the busbar layer (300). The thickness of the busbar layer (300) may be less than 1 mm. The thickness of the busbar layer (300) may be 0.2 mm.

[0167] Each busbar layer (300) may include an element portion (310), a first busbar portion (320), and a second busbar portion (330). The first busbar portion (320), the second busbar portion (330), and the element portion (310) of each busbar layer (300) may contact the first busbar portion (320), the second busbar portion (330), and the element portion (310) of the neighboring busbar layer (300) in the stacking direction, respectively. Here, the stacking direction may be the thickness direction. In each busbar layer (300), the thicknesses of the first busbar portion (320), the second busbar portion (330), and the element portion (310) may be the same.

[0168]

[0169] [Element Department]

[0170] The element portion (310) of each busbar layer (300) may include a melting portion (M) that melts when overcurrent is applied.

[0171] Each element portion (310) may include a hole (H). Here, each element portion (310) may mean an element portion (310) of each busbar layer (300). The same applies hereinafter.

[0172] A hole (H) can be formed by penetrating the element portion (310) in the stacking direction. The hole (H) can define a cutting portion (M). The hole (H) of each element portion (310) can be connected in the stacking direction with the hole (H) of the neighboring element portion (310) in the stacking direction (Fig. 6).

[0173] Each element portion (310) may include a groove (G). The groove (G) may be formed inwardly from a widthwise end of the element portion (310) and may be open on both sides in the stacking direction. The groove (G) may define a cutting portion (M). The groove (G) of each element portion (310) may be connected in the stacking direction with the groove (G) of an adjacent element portion (310) in the stacking direction (Fig. 6).

[0174] The plurality of cutting sections (M) of the plurality of element sections (310) can at least partially overlap each other in the length direction and width direction (Fig. 6). At this time, as described above, the first bus bar section (320), the second bus bar section (330) and the element section (310) of each bus bar layer (300) can contact the first bus bar section (320), the second bus bar section (330) and the element section (310) of the bus bar layer (300) adjacent to each other in the stacking direction, respectively.

[0175] Accordingly, even if the melting portion (M) of some busbar layers (300) is first broken due to temperature change, impact, or thermal energy, the heat generation, temperature, etc. of the fuse-integrated busbar (30) when normal current is applied may be similar to the case where the melting portion (M) is not broken. This is because the current that flowed through the first broken melting portion (M) can be distributed and flow through a plurality of melting portions (M) in the stacking direction that are very adjacent to the first broken melting portion (M). Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) can be improved.

[0176] In addition, since the fuse portion (M) can be supported or interfered with by an adjacent fuse portion (M) in the stacking direction, the fuse portion (M) is difficult to deform. Accordingly, the durability of the fuse-integrated bus bar (30) as a fuse can be improved.

[0177] In addition, the fuse-integrated bus bar (30) can uniformly and stably wrap the plurality of fuse-cutting sections (M) of the plurality of element sections (310). Accordingly, the fuse-integrated bus bar (30) can improve its fuse-integrated performance.

[0178] In each busbar layer (300), the thickness of the cutting portion (M) may be the same as the thickness of the first busbar portion (320), the second busbar portion (330), and the element portion (310).

[0179] The cutting part (M) of each element part (310) can be in contact with the cutting part (M) of the neighboring element part (310) in the stacking direction.

[0180] Accordingly, even if the melting portion (M) of some busbar layers (300) is first broken due to temperature change, impact, or thermal energy, the amount of heat generated, temperature, etc. of the fuse-integrated busbar (30) when normal current is applied may be similar to the case where the melting portion (M) is not broken. This is because the current that flowed through the first broken melting portion (M) can be distributed and flow through a plurality of melting portions (M) in the stacking direction that are very adjacent to and in contact with the first broken melting portion (M). Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) can be improved.

[0181] In addition, since the fuse portion (M) can be supported or interfered with by the fuse portion (M) that is in contact with the stacking direction, the fuse portion (M) is difficult to deform. Accordingly, the durability of the fuse-integrated bus bar (30) as a fuse can be improved.

[0182] In addition, air (oxygen) can be reduced or eliminated between a pair of adjacent fuse portions (M) in the stacking direction. Accordingly, the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0183] The cutting section (M) of each element section (310) may include a first sub-cutting section (MS1) and a second sub-cutting section (MS2).

[0184] The first sub-end portion (MS1) and the second sub-end portion (MS2) can be spaced apart in the width direction with a hole (H) between them. The first sub-end portion (MS1) and the second sub-end portion (MS2) can be connected in parallel to each other.

[0185] Accordingly, even if one of the first sub-fuse section (MS1) and the second sub-fuse section (MS2) of the fuse section (M) of each busbar layer (300) is first cut off due to temperature change, impact, or thermal energy, the normal current applied to each busbar layer (300) can flow through the other sub-fuse section. Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) can be improved.

[0186] The plurality of first sub-end portions (MS1) of the plurality of element portions (310) can at least partially overlap each other in the longitudinal direction and the width direction. The plurality of second sub-end portions (MS2) of the plurality of element portions (310) can at least partially overlap each other in the longitudinal direction and the width direction. At this time, as described above, the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of each bus bar layer (300) can contact the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of the bus bar layer (300) adjacent to each other in the stacking direction, respectively.

[0187] Accordingly, even if one of the sub-melting parts of some busbar layers (300) is first broken due to temperature change, impact, or thermal energy, the amount of heat generated, temperature, etc. of the fuse-integrated busbar (30) when normal current is applied may be similar to the case where the sub-melting part is not broken. This is because the current that flowed through one of the first broken sub-melting parts may flow through another sub-melting part adjacent in the width direction or may be distributed and flow through a plurality of sub-melting parts adjacent in the stacking direction. Accordingly, the energy efficiency, quality, and durability of the fuse-integrated busbar (30) may be improved.

[0188] In addition, since the sub-fuse section can be supported or interfered with by the adjacent sub-fuse section in the stacking direction, it is difficult for the sub-fuse section to be deformed. Accordingly, the durability of the fuse-integrated bus bar (30) as a fuse can be improved.

[0189] In addition, the arc-extinguishing member (34) can uniformly and stably wrap a plurality of first sub-end sections (MS1) and a plurality of second sub-end sections (MS2) of a plurality of element sections (310). Accordingly, the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0190] The width or thickness of the cutting portion (M) may be smaller than the width or thickness of the adjacent portions on the outer sides of the longitudinal ends of the cutting portion (M). Each element portion (310) may include a plurality of cutting portions (M) that are spaced apart from each other in the longitudinal direction and connected in series with each other. For example, the cutting portion (M) may include first, second, and third cutting portions (M1, M2, M3) that are spaced apart from each other in the longitudinal direction and connected in series with each other.

[0191] Accordingly, at least one longitudinal melting portion (M) can be reliably melted. In particular, even if the sum total of the thicknesses of the melting portions (M) of the plurality of busbar layers (300) of the first busbar (32) is equal to the sum total of the thicknesses of the first busbar portion (320) or the second busbar portion (330) of the plurality of busbar layers (300), the melting portion (M) can be reliably melted when an overcurrent is applied. Therefore, the fuse-integrated busbar (30) can reliably block an overcurrent.

[0192] The first, second and third terminations (M1, M2, M3) may each include the first sub-terminal (MS1) and the second sub-terminal (MS2) described above.

[0193]

[0194] [Bus Babu 1 and Bus Babu 2]

[0195] The first bus bar portion (320) and the second bus bar portion (330) may be formed integrally with the element portion (310). The first bus bar portion (320) and the second bus bar portion (330) may be formed to extend from both ends of the element portion (310) in the longitudinal direction to both sides.

[0196] In this way, the fuse-integrated bus bar (30) may include a first bus bar (32) formed by stacking a bus bar layer (300) in which an element portion (310), a first bus bar portion (320), and a second bus bar portion (330) are integrally formed, and a shielding member (34) described later.

[0197] Accordingly, since the first busbar (32) has a fuse function, there is no need to manufacture or purchase a fuse separately, and there is no need to install a fuse between two busbars as in the past. Therefore, the number and types of parts can be reduced, and manufacturing costs can be reduced.

[0198] In addition, since the first / second busbar portions (320, 330) and the element portion (310) are formed integrally, energy efficiency, quality, and quality uniformity can be improved compared to the conventional case where a separate fuse is combined between the busbars. In addition, the thickness, width, and shape of the first / second busbar portions (320, 330) and the element portion (310) can be optimized so that resistance and heat generation are reduced when normal current is applied and reliably melted when overcurrent is applied.

[0199] In addition, since a plurality of busbar layers (300) are stacked to form the first busbar (32), the thickness of each busbar layer (300) can be reduced. Accordingly, since each busbar layer (300) can be easily deformed, even if force is applied to the fuse-integrated busbar (30), the melting portion (M) can be protected. For example, a compressive force or a tensile force applied to the busbar layer (300) (e.g., in the longitudinal direction) due to temperature change or impact, etc. can be relieved by deformation (e.g., bending or straightening) of a portion (e.g., the first busbar portion or the second busbar portion) other than the melting portion (M) of the busbar layer (300), so that the melting portion (M) can be protected. Accordingly, the durability of the fuse-integrated busbar (30) as a fuse can be improved.

[0200] In addition, since the thickness of each busbar layer (300) can be reduced, each busbar layer (300) can be easily deformed (e.g., bent) to suit the shape or position of the counterpart. At this time, each busbar layer (300) can be deformed and then fastened to the counterpart, or each busbar layer (300) can be deformed after being fastened to the counterpart. Accordingly, the fuse-integrated busbar (30) can be easily installed and maintained.

[0201] In addition, since the thickness of each busbar layer (300) can be reduced, the melting portion (M) of each busbar layer (300) can be reliably melted when overcurrent is applied. Accordingly, the fuse-integrated busbar (30) can reliably block overcurrent. In contrast, if the first busbar (32) is not composed of multiple layers and thus has a large thickness, the melting portion (M) may be incompletely melted when overcurrent is applied, resulting in failure to block overcurrent.

[0202] Among the longitudinal ends of the first bus bar portion (320), the end opposite to the end on the element portion (310) side can be joined (e.g., welded) to the neighboring first bus bar portion (320) (in the stacking direction). The same applies to the second bus bar portion (330).

[0203] The first bus bar (320) and / or the second bus bar (330) may be wrapped with an insulating tube (TPV, etc.).

[0204]

[0205] [Absence of Soho]

[0206] The arc-extinguishing member (34) can surround a plurality of element parts (310) of a plurality of busbar layers (300). The arc-extinguishing member (34) can extinguish an arc.

[0207] The arc extinguishing member (34) may expand when an arc occurs or the ambient temperature is higher than a predetermined temperature. For example, when an arc occurs at the cutting part (M), the arc extinguishing member (34) may absorb heat energy and expand. The expansion rate of the arc extinguishing member (34) may be controlled by adjusting the components or ratio of the components of the arc extinguishing member (34).

[0208] Accordingly, the spread of arcs, flames or heat can be easily prevented with a simple configuration and low cost, and damage caused by the spread of arcs, flames or heat can be prevented.

[0209] In addition, since external contact of the cutting part (M) is blocked by the expanded protective member (34), short circuit, fire, safety accidents, etc. can be prevented.

[0210] In addition, since the protective member (34) does not include a protective thread used in a conventional fuse, packaging or installation of the protective member (34) is easy, and the protective member (34) can be made smaller and lighter.

[0211] The protective member (34) may be a foam formed by foaming a material including synthetic rubber.

[0212] Accordingly, the arc-extinguishing member (34) can be brought into close contact with the element portion (310) by the foaming pressure applied when the synthetic rubber foam is formed, so that the air (oxygen) around the element portion (310) can be reduced or eliminated. Accordingly, the arc-extinguishing member (34) can be easily manufactured with a simple configuration and low cost, and the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved.

[0213] In addition, synthetic rubber generally has excellent elasticity and heat resistance, so the protective member (34) can stably expand while absorbing heat energy. Accordingly, the spread of arcs, flames, or heat can be stably blocked with a simple configuration and low cost.

[0214] In addition, since synthetic rubber foam is used instead of the protective material of a conventional fuse, packaging or installation of the protective material (34) is easy, and the protective material (34) can be made smaller and lighter.

[0215] Synthetic rubber may include silicone rubber.

[0216] Accordingly, silicone rubber foam can stably expand while absorbing heat energy. This is because silicone rubber foam has excellent elasticity and heat resistance. Therefore, it can reliably prevent the spread of arcs, flames, or heat with a simple configuration and low cost.

[0217] Here, the foam formed by foaming synthetic rubber including silicone rubber may refer to known silicone foam.

[0218] The protective member (34) may include a hole (H') and / or a groove (G') corresponding to the hole (H) and / or the groove (G) of the element portion (310). The inner surface of the hole (H') and / or the groove (G') of the protective member (34) may surround the inner surface of the hole (H) and / or the groove (G) of the element portion (310).

[0219]

[0220] [sleeve]

[0221] The cover (36) can wrap a plurality of element parts (310) and a protective member (34).

[0222] Accordingly, the arc-protecting member (34) can be protected. In addition, since the state in which the arc-protecting member (34) surrounds the plurality of element parts (310) can be stably maintained by the cover (36), the arc-protecting performance of the fuse-integrated bus bar (30) can be improved.

[0223] The cover (36) may include an insertion portion (T). The insertion portion (T) may be inserted into a plurality of holes (H) of a plurality of element portions (310) (Fig. 3, Fig. 6). The insertion portion (T) may be inserted into a hole (H') of a protective member (34) (Fig. 3, Fig. 6).

[0224] A protective member (34) may be interposed between the inner surface of the plurality of holes (H) and the outer surface of the insertion portion (T) (Fig. 3, Fig. 6).

[0225] Accordingly, the arc-extinguishing member (34) can be brought into close contact with the inner surfaces of the plurality of holes (H) by the insertion portion (T) of the cover (36), and the close contact state can be stably maintained. Accordingly, the air (oxygen) inside the plurality of holes (H), i.e., the air (oxygen) around the cutting portion (M), can be reduced or eliminated. Therefore, the arc-extinguishing performance of the arc-extinguishing member (34) can be easily improved with a simple configuration and low cost.

[0226] The cover (36) may include a protrusion (P). The protrusion (P) may be inserted into a plurality of grooves (G) of a plurality of element parts (310) (Fig. 3, Fig. 6). The protrusion (P) may be inserted into a groove (G') of the protective member (34) (Fig. 3, Fig. 6).

[0227] A protective member (34) may be interposed between the inner surface of the plurality of grooves (G) and the outer surface of the protrusion (P) (Fig. 3, Fig. 6).

[0228] The cover (36) can be installed by connecting the first cover (36A) and the second cover (36B) in a stacking direction with a plurality of element parts (310) and a protective member (34) interposed therebetween (Fig. 4).

[0229]

[0230] [Second embodiment of integrated fuse busbar]

[0231] The fuse-integrated busbar according to the second embodiment may include a second busbar and a fuse-protecting member (34). The fuse-integrated busbar according to the second embodiment may further include a cover (36).

[0232] The second busbar may include an element portion (310), a first busbar portion (320), and a second busbar portion (330). That is, unlike the first busbar (300) described above, the second busbar may not be formed by stacking multiple busbar layers (300). For example, the second busbar may be formed by a single busbar layer (300).

[0233] The element section (310) may include a melting section (M) that melts when overcurrent is applied.

[0234] The first bus bar portion (320) and the second bus bar portion (330) may be formed integrally with the element portion (310). The first bus bar portion (320) and the second bus bar portion (330) may be formed to extend from both ends of the element portion (310) in the longitudinal direction to both sides.

[0235] The arc extinguishing member (34) can surround the element portion (310). The arc extinguishing member (34) can extinguish an arc. The arc extinguishing member (34) can expand when an arc occurs or the ambient temperature is higher than a predetermined temperature.

[0236] Accordingly, since the second busbar functions as a fuse, there is no need to manufacture or purchase a separate fuse, nor is there a need to install a fuse between the two busbars as was done previously. This reduces the number and type of components, thereby lowering manufacturing costs.

[0237] In addition, since the first / second busbar portions (320, 330) and the element portion (310) are formed integrally, energy efficiency, quality, and quality uniformity can be improved compared to the conventional case where a separate fuse is combined between the busbars. In addition, the thickness, width, and shape of the first / second busbar portions (320, 330) and the element portion (310) can be optimized so that resistance and heat generation are reduced when normal current is applied and reliably melted when overcurrent is applied.

[0238] In addition, it can easily block the spread of arcs, flames or heat with a simple configuration and low cost, and prevent damage caused by the spread of arcs, flames or heat.

[0239] In addition, since external contact of the cutting part (M) is blocked by the expanded protective member (34), short circuit, fire, safety accidents, etc. can be prevented.

[0240] In addition, since the protective member (34) does not include a protective thread used in a conventional fuse, packaging or installation of the protective member (34) is easy, and the protective member (34) can be made smaller and lighter.

[0241] The protective member (34) may be a foam formed by foaming a material including synthetic rubber.

[0242] Matters not mentioned in relation to the fuse-integrated bus bar according to the second embodiment can be inferred from the fuse-integrated bus bar (30) according to the first embodiment described above.

[0243]

[0244] [Manufacturing method of integrated fuse busbar]

[0245] Referring to Fig. 9, the manufacturing method (S500) of a fuse-integrated bus bar may include a placement process (S510), a pouring process (S520), and a curing process (S530).

[0246] In the arrangement process (S510), the element part (310) of the first or second busbar of the fuse-integrated busbar according to the first or second embodiment described above can be arranged inside the mold.

[0247] In the injection process (S520), a foaming material containing synthetic rubber can be injected and foamed inside the mold. For example, the foaming material can include a synthetic rubber (e.g., silicone rubber) composition and a foaming agent. The foaming material can further include a curing agent. The foaming material can be a material that combines a synthetic rubber composition and a material containing a foaming agent. The foaming material can be a material that combines a synthetic rubber composition, a foaming agent, and a curing agent.

[0248] In the curing process (S530), the foaming material can be cured.

[0249] Accordingly, the arc-extinguishing member (34) of the fuse-integrated bus bar (30) can be easily manufactured with a simple configuration and low cost. In addition, the arc-extinguishing performance of the fuse-integrated bus bar (30) can be improved. This is because the arc-extinguishing member (34) can be formed in close contact with the element portion (310) by the foaming pressure applied when the synthetic rubber foam is formed, so that the air (oxygen) around the element portion (310) can be reduced or eliminated.

[0250]

[0251] It should be understood that the above-described embodiments are illustrative in all respects and not restrictive, and the scope of the present invention will be determined by the claims that follow, rather than by the detailed description set forth above. Furthermore, the meaning and scope of the claims that follow, as well as all possible modifications and variations derived from their equivalent concepts, should be construed as encompassing the scope of the present invention.

[0252] Although the present invention has been described with reference to the drawings exemplified above, it is to be understood that the present invention is not limited to the embodiments and drawings disclosed herein, and that various modifications may be made by those skilled in the art within the scope of the technical idea of ​​the present invention. Furthermore, even if the operational effects according to the configuration of the present invention have not been explicitly described while describing the embodiments of the present invention, it is natural that the effects predictable by the corresponding configuration should also be acknowledged.

Claims

1. A first bus bar (32) formed by stacking a plurality of bus bar layers (300) including an element part (310) including a melting part (M) that melts when overcurrent is applied, and a first bus bar part (320) and a second bus bar part (330) formed integrally with the element part (310) and extending to both sides from both ends of the longitudinal direction of the element part (310), and A plurality of busbar layers (300) including a plurality of element parts (310) surrounding the plurality of busbar layers (300) and including an arc-extinguishing member (34) that extinguishes the arc. Busbar with integrated fuse.

2. In claim 1, A fuse-integrated bus bar further comprising a cover (36) covering the plurality of element sections (310) and the fuse member (34).

3. In claim 2, Each of the above element parts (310) includes a hole (H) that is formed by penetrating the element part (310) in the stacking direction and defines the cutting part (M). The hole (H) of each of the above element parts (310) is connected in the stacking direction with the hole (H) of the neighboring element part (310), The above cover (36) includes an insertion part (T) that is inserted into a plurality of holes (H) of the plurality of element parts (310), A fuse-integrated bus bar, in which the protective member (34) is interposed between the inner surface of the plurality of holes (H) and the outer surface of the insertion portion (T).

4. In any one of claims 1 to 3, The first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of each of the above bus bar layers (300) are in contact with the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of the adjacent bus bar layers (300) in the stacking direction, respectively. A fuse-integrated bus bar, wherein the plurality of the above-described fuse portions (M) of the plurality of above-described element portions (310) overlap each other at least partially in the lengthwise and widthwise directions.

5. In claim 4, A fuse-integrated bus bar, wherein the fuse portion (M) of each of the above-mentioned element portions (310) is in contact with the fuse portion (M) of the neighboring element portion (310) in the stacking direction.

6. In claim 1 or claim 2, The fuse-integrated bus bar, wherein the fuse section (M) of each of the above-mentioned element sections (310) includes a first sub-fuse section (MS1) and a second sub-fuse section (MS2) that are spaced apart in the width direction with a hole (H) therebetween and connected in parallel to each other.

7. In claim 6, The first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of each of the above bus bar layers (300) are in contact with the first bus bar portion (320), the second bus bar portion (330) and the element portion (310) of the adjacent bus bar layers (300) in the stacking direction, respectively. The plurality of first sub-end portions (MS1) of the plurality of element portions (310) overlap each other at least partially in the length direction and width direction, A fuse-integrated bus bar, wherein the plurality of second sub-end sections (MS2) of the plurality of element sections (310) overlap each other at least partially in the length and width directions.

8. In any one of claims 1 to 7, The width or thickness of the above-mentioned cutting portion (M) is smaller than the width or thickness of the adjacent portion on the outer side of both longitudinal ends of the cutting portion (M), A fuse-integrated bus bar, wherein each of the above-mentioned element sections (310) includes a plurality of the above-mentioned fuse sections (M) spaced apart from each other in the longitudinal direction and connected to each other in series.

9. In any one of claims 1 to 8, The above-mentioned fuse-integrated bus bar (34) expands when an arc occurs or the surrounding temperature is higher than a predetermined temperature.

10. In claim 9, The above-mentioned fuse-integrated bus bar (34) is a foamed chain formed by foaming a material including synthetic rubber.

11. An element part (310) including a melting part (M) that melts when overcurrent is applied, and a second bus bar including a first bus bar part (320) and a second bus bar part (330) formed integrally with the element part (310) and extending to both sides from both ends of the longitudinal direction of the element part (310); and It includes a protective member (34) that surrounds the above element portion (310) and protects the arc, The above-mentioned fuse-integrated bus bar is a foamed body formed by foaming a material including synthetic rubber that expands when an arc occurs or the surrounding temperature is higher than a predetermined temperature.

12. In claim 10 or claim 11, The above synthetic rubber is a fuse-integrated bus bar containing silicone rubber.

13. One or more battery modules (10) each comprising one or more battery cells; One or more connectors (20) each electrically connectable to an external device; and Including at least one fuse-integrated bus bar (30) according to any one of claims 1 to 12, At least some of the above one or more fuse-integrated bus bars (30) are arranged between at least some of the above one or more battery modules (10) and at least some of the above one or more connectors (20) to directly electrically connect at least some of the above battery modules (10) and at least some of the above connectors (20), or are arranged between two or more of the above battery modules (10) to directly electrically connect the two or more of the above battery modules (10) to each other. Battery pack.

14. In a method for manufacturing a fuse-integrated busbar according to any one of claims 1 to 12, A placement process (S510) for arranging the above element portion (310) inside a mold; A pouring process (S520) for pouring and foaming a foaming material containing synthetic rubber into the mold; and Including a curing process (S530) for curing the foam material. A method for manufacturing a fuse-integrated busbar.

Images