Battery cell assembly and method for manufacturing same

Abstract

According to exemplary embodiments, a battery cell assembly is provided. The battery cell assembly comprises: a plurality of battery cells arranged in a first direction; and an integrated circuit assembly covering the plurality of battery cells, wherein the integrated circuit assembly includes an insulating frame including an insulating material and an integrated circuit mounted on the insulating frame and configured to be electrically connected to the plurality of battery cells, the insulating frame includes a first side facing the plurality of battery cells, and the first side is rib-free.

Description

Battery cell assembly and method of manufacturing it

[0001] The present invention relates to a battery cell assembly and a method for manufacturing the same. This application claims the benefit of Korean Application No. 10-2024-0032798, filed March 7, 2024, which is incorporated herein by reference in its entirety.

[0002] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. They are widely used as a power source for various wireless devices, including handsets, laptops, and cordless vacuum cleaners. Recently, improved energy density and economies of scale have dramatically reduced the per-unit manufacturing cost of secondary batteries. Furthermore, as the range of battery electric vehicles (BEVs) has increased to match that of fuel-powered vehicles, the primary use of secondary batteries is shifting from mobile devices to mobility.

[0003] The technological development trend for secondary batteries for mobility is improving energy density and safety. The safety of secondary batteries for mobility is crucial, as it directly impacts the lives of passengers. Safety in secondary batteries can be achieved through mechanical robustness, reliable electrical insulation, and delayed heat transfer in the event of thermal runaway.

[0004] The technical idea of ​​the present invention is to provide a battery cell assembly with improved safety when subjected to external impact and a method for manufacturing the same.

[0005] According to exemplary embodiments of the present invention for solving the above-described problem, a battery cell assembly is provided. The battery cell assembly includes a plurality of battery cells arranged in a first direction; and an integrated circuit assembly covering the plurality of battery cells, the integrated circuit assembly including an insulating frame including an insulating material and an integrated circuit mounted on the insulating frame and configured to be electrically connected to the plurality of battery cells, and the insulating frame includes a first side facing the plurality of battery cells, and the first side is rib-free.

[0006] The insulating frame includes a plurality of terminal supports arranged on the first side and along the first direction, and each of the plurality of terminal supports includes a through hole.

[0007] Each of the plurality of terminal supports includes an inner wall defining the through hole, and the inner wall of each of the plurality of terminal supports is solid.

[0008] Each of the plurality of battery cells includes a positive terminal and a negative terminal, and each of the plurality of terminal supports overlaps the positive terminal and the negative terminal of a corresponding one of the plurality of battery cells in a second direction perpendicular to the first direction.

[0009] The length of the third direction perpendicular to each of the first and second directions of the through hole is equal to the length of each of the plurality of terminal supports in the third direction.

[0010] The insulating frame is on the first side and includes a plurality of interposition portions alternating with the plurality of terminal support portions in the first direction.

[0011] The integrated circuit assembly is mounted on a second side of the insulating frame opposite the first side, and the insulating frame includes a plurality of ribs on the second side.

[0012] The above plurality of ribs overlap with the above plurality of intervening parts.

[0013] According to exemplary embodiments, a method of manufacturing a battery cell assembly is provided. The method includes the steps of assembling a plurality of battery cells and an integrated circuit assembly; inserting a reinforcing pin into a through hole of an insulating frame of the integrated circuit assembly, wherein a length of the reinforcing pin is greater than a length of the insulating frame; and welding the positive terminals and the negative terminals of the plurality of battery cells.

[0014] The plurality of battery cells are arranged in a first direction, and the reinforcing pin overlaps the positive terminals and the negative terminals of the plurality of battery cells in a second direction perpendicular to the first direction.

[0015] According to exemplary embodiments, a battery cell assembly is provided. The battery cell assembly includes: a first integrated circuit assembly including a plurality of battery cells arranged in a first direction; a first insulating frame including an insulating material and a first integrated circuit mounted on the first insulating frame and configured to be electrically connected to the plurality of battery cells; and a second integrated circuit assembly including a second insulating frame including an insulating material and a second integrated circuit mounted on the second insulating frame and configured to be electrically connected to the plurality of battery cells, wherein the first insulating frame includes a first side facing the plurality of battery cells and a second side opposite the first side, and the first side is rib-free, and the second insulating frame includes a third side facing the plurality of battery cells and a fourth side opposite the third side, and the third side is rib-free.

[0016] The first insulating frame includes a plurality of first terminal supports arranged on the first side and along the first direction, each of the plurality of first terminal supports including a first through hole, and the second insulating frame includes a plurality of second terminal supports arranged on the third side and along the first direction, and each of the plurality of second terminal supports including a second through hole.

[0017] Each of the plurality of first terminal supports includes a first inner wall defining the first through hole, and the first inner wall of each of the plurality of first terminal supports is solid, and each of the plurality of second terminal supports includes a second inner wall defining the second through hole, and the second inner wall of each of the plurality of second terminal supports is solid.

[0018] The first and second integrated circuit assemblies are spaced apart in a second direction perpendicular to the first direction, each of the plurality of battery cells includes a positive terminal and a negative terminal, and each of the plurality of first and second terminal supports overlaps the positive terminal and the negative terminal of a corresponding one of the plurality of battery cells in a second direction perpendicular to the first direction.

[0019] The length of the first through hole in the third direction perpendicular to each of the first and second directions is the same as the length of each of the plurality of first terminal supports in the third direction, and the length of the second through hole in the third direction is the same as the length of each of the plurality of second terminal supports in the third direction.

[0020] According to exemplary embodiments of the present invention, a battery cell assembly includes an insulating frame including a plurality of battery cells and a first side that is rib-free and faces the plurality of battery cells. Accordingly, damage to the plurality of battery cells can be prevented even when an external impact is transmitted to the battery cell assembly.

[0021] The effects that can be obtained from the exemplary embodiments of the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of the present disclosure pertain from the following description. In other words, unintended effects resulting from practicing the exemplary embodiments of the present disclosure can also be derived by those skilled in the art from the exemplary embodiments of the present disclosure.

[0022] FIG. 1 is a plan view illustrating a battery pack according to exemplary embodiments.

[0023] Figure 2 is a perspective view showing the battery cell assembly of Figure 1.

[0024] Figure 3 is a front view of the battery cell assembly of Figure 2.

[0025] Figure 4 is a perspective view of a first insulating frame of a battery cell assembly.

[0026] Figure 5 is a plan view of the first insulating frame of the battery cell assembly.

[0027] Figure 6 is a perspective view of a first insulating frame of a battery cell assembly.

[0028] Figure 7 is a plan view of the first insulating frame of the battery cell assembly.

[0029] FIG. 8 is a flowchart illustrating a method of providing a battery cell assembly according to exemplary embodiments.

[0030] FIGS. 9 and 10 are perspective views illustrating a method of providing a battery cell assembly according to exemplary embodiments.

[0031] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, it should be noted that the terms and words used in this specification and claims should not be construed as limited to their conventional or dictionary meanings. Based on the principle that the inventor can appropriately define the concepts of terms to best explain his or her invention, they should be interpreted in a way that aligns with the technical spirit of the present invention.

[0032] Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that there may be various equivalents and modified examples that can replace them at the time of filing this application.

[0033] In addition, when describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description is omitted.

[0034] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or schematically illustrated for clearer explanation. Accordingly, the sizes and proportions of each component do not fully reflect the actual sizes or proportions.

[0035]

[0036] (Example 1)

[0037] FIG. 1 is a plan view illustrating a battery pack according to exemplary embodiments.

[0038] Referring to FIG. 1, a battery pack (100) may include a pack housing (110) and a plurality of battery cell assemblies (120). The battery pack (100) may be a final product mounted in an application such as a vehicle.

[0039] The pack housing (110) can provide a space for mounting battery cell assemblies (120). The pack housing (110) can include a base plate (111) and side walls (112, 113, 114, 115).

[0040] Here, two directions substantially parallel to the mounting surface of the base plate (111) (i.e., the surface facing the battery cell assembly (120)) are defined as the X direction and the Y direction, and a direction substantially perpendicular to the mounting surface of the base plate (111) is defined as the Z direction. The X direction, the Y direction, and the Z direction may be substantially perpendicular to each other.

[0041] The base plate (111) and the side walls (112, 113) may each be provided by an extrusion process. The extrusion direction of each of the base plate (111) and the side walls (112, 113) may be the X direction. The side walls (114, 115) may also be provided by an extrusion process. The side walls (112, 113, 114, 115) may be substantially perpendicular to the base plate (111).

[0042] According to exemplary embodiments, the base plate (111) and side walls (112, 113) may be joined by friction stir welding. The base plate (111) may include a plurality of unit plates joined by friction stir welding.

[0043] The pack housing (110) may include a center beam (116). The center beam (116) may extend in the X direction. The center beam (116) may be interposed between the side walls (112, 113). The center beam (116) may be included in a center plate, which is one of a plurality of unit plates that are friction stir welded to each other. Accordingly, the center beam (116) may be formed together with the center plate, and the center beam (116) may be an integral and continuous element with the center plate.

[0044] The base plate (111) may include a plurality of cooling channels. The plurality of cooling channels may provide passages for the movement of a coolant, such as water, for example. The plurality of cooling channels may be formed by an extrusion process. The plurality of cooling channels may extend in the X direction. The plurality of cooling channels may be spaced apart in the Y direction.

[0045] A plurality of battery cell assemblies (120) may be arranged on a base plate (111) of a pack housing (110). The base plate (111) may support the plurality of battery cell assemblies (120). Side walls (112, 113, 114, 115) may horizontally surround the plurality of battery cell assemblies (120). The side walls (112, 113, 114, 115) may protect the plurality of battery cell assemblies (120).

[0046] Hereinafter, the technical concept of the present invention will be described based on an embodiment in which the battery pack (100) is of a modular type and each of the plurality of battery cell assemblies (120) does not include a module frame. However, this is for illustrative purposes and does not limit the technical concept of the present invention in any sense. A person skilled in the art will easily arrive at an embodiment in which the battery pack may be of a modular type and each of the plurality of battery cell assemblies includes a module frame based on the description herein.

[0047] Thermal Interface Material (TIM) layers may be provided between the base plate (111B) of the pack housing (110) and the plurality of battery cell assemblies (120). The TIM layers may include a resin composition. The TIM layers may be provided by a thermal resin application process.

[0048] The resin composition may be a room temperature curable composition. That is, the curing reaction of the resin composition may be initiated and proceed at room temperature. The curing reaction of the resin composition may be accelerated at a temperature higher than room temperature. The curing reaction rate of the resin composition at a temperature higher than room temperature may be faster than the curing reaction rate of the resin composition at room temperature. As a non-limiting example, the subject of the resin composition may be any one of a silicone resin, a polyol resin, an epoxy resin, and an acrylic resin.

[0049] The center beam (116) can extend in the X direction. The center beam (116) can isolate a plurality of battery cell assemblies (120) in the Y direction. The center beam (116) can be interposed between the plurality of battery cell assemblies (120).

[0050] In Fig. 1, the arrangement of the plurality of battery cell assemblies (120) can be said to be a 3 * 2 arrangement. The arrangement of the plurality of battery cell assemblies (120) disclosed in Fig. 1 is a non-limiting example and does not limit the technical idea of ​​the present invention in any sense. A person skilled in the art will be able to easily arrive at a plurality of battery cell assemblies (120) arranged in M ​​* N (wherein, M and N are each integers greater than or equal to 2) based on the description herein.

[0051] The battery pack (100) may further include leads coupled to side walls (112, 113, 114, 115) of the pack housing (110). The leads may cover elements mounted inside the battery pack (100), such as a plurality of battery cell assemblies (120) and electrical components. The leads may be secured to the pack housing (110) by mechanical coupling means, such as bolting.

[0052] The battery pack may further include exhaust devices coupled to the sidewalls (114, 115). Either of the sidewalls (114, 115) may include exhaust holes connected to the exhaust devices. The exhaust devices may be configured to delay thermal propagation by releasing high-temperature gas within the battery pack (100) to the outside when a thermal runway event occurs in the plurality of battery cell assemblies (120).

[0053] Here, thermal runaway of multiple battery cell assemblies (120) is a state in which temperature changes of multiple battery cell assemblies (120) further accelerate the temperature change, which is an uncontrollable positive feedback. Multiple battery cell assemblies (120) in a state of thermal runaway exhibit a rapid temperature increase and emit a large amount of high-pressure gas and combustion debris.

[0054] The battery pack (100) may further include a Battery Management System (BMS). The BMS may be configured to perform monitoring, balancing, and control of the battery pack (100). Monitoring of the battery pack (100) may include monitoring the voltage and current of specific nodes within a plurality of battery cell assemblies (120) and monitoring the temperature distribution of set locations within the battery pack (100).

[0055] Balancing of a battery pack (100) is an operation that reduces the deviation between multiple battery cell assemblies (120). Control of the battery pack (100) includes preventing overcharge, overdischarge, and overcurrent. Through monitoring, balancing, and control, the battery pack (100) can operate under optimal conditions, thereby preventing shortening of the lifespan of each of the multiple battery cell assemblies (120).

[0056] The battery pack (100) may further include additional electrical components, such as a cooling device, a PRA (Power Relay Assembly), and a safety plug. The cooling device may include a cooling fan. The cooling fan may prevent overheating of each of the plurality of battery cell assemblies (120) by circulating air inside the battery pack (100). The PRA may be configured to supply or cut off power from the high-voltage battery to an external load (e.g., a vehicle motor). The PRA may protect the plurality of battery cell assemblies (120) and the external load (e.g., a vehicle motor) by cutting off power supply to the external load (e.g., a vehicle motor) in a situation where an abnormal voltage, such as a voltage surge, occurs. Additional electrical components may be interposed between the plurality of battery cell assemblies (120) and the sidewall (115). The space between the battery cell assemblies (120) and the sidewall (115) may also be referred to as an electrical component mounting area.

[0057] The battery pack (100) may further include a plurality of inter-bus bars configured to electrically connect a plurality of battery cell assemblies (120). The plurality of battery cell assemblies (120) may be connected in series by the plurality of inter-bus bars. Accordingly, the battery pack (100) may be configured to output a high voltage to an external load (e.g., a vehicle motor).

[0058]

[0059] (Example 2)

[0060] FIG. 2 is a perspective view showing the battery cell assembly (120) of FIG. 1.

[0061] Figure 3 is a front view of the battery cell assembly (120) of Figure 2.

[0062] In FIGS. 2 and 3, the definitions of the X direction, Y direction, and Z direction are based on the case where the battery cell assembly (120) is arranged on the pack housing (110, see FIG. 1). In FIGS. 2 and 3, the X direction is a direction in which a plurality of battery cells (121) are arranged, the Y direction is a direction in which the first integrated circuit assembly (123) and the second integrated circuit assembly (124) are spaced apart, and the Z direction can be substantially perpendicular to each of the X direction and the Y direction.

[0063] Referring to FIGS. 2 and 3, each of the plurality of battery cell assemblies (120) may include a plurality of battery cells (121), a first integrated circuit assembly (123), a second integrated circuit assembly (124), and FFC (Flexible Flat Cable) assemblies (127).

[0064] Each of the plurality of battery cells (121) may be a lithium ion battery. The plurality of battery cells (121) may be arranged in the X direction. The plurality of battery cells (121) may include a case (121C), an electrode assembly, a positive terminal (121P), a negative terminal (121N), and a folding tape (121A). The battery cell (121) may further include an electrolyte.

[0065] According to exemplary embodiments, the battery cell (121) may include one of a cylindrical battery cell, a prismatic battery cell, and a pouch-type battery cell. The electrode assembly of the cylindrical battery cell is housed in a cylindrical metal can. The electrode assembly of the prismatic battery cell is housed in a prismatic metal can. The electrode assembly of the pouch-type battery cell is housed in a pouch case including an aluminum laminate sheet. Hereinafter, the technical idea of ​​the present invention will be described based on an example in which the battery cell (121) includes a pouch-type battery cell, but one of ordinary skill in the art will be able to easily arrive at an example in which the battery cell (121) includes one of a cylindrical battery cell and a prismatic battery cell based on the description herein.

[0066] The electrode assembly may include an anode, a cathode, and a separator interposed between the anode and the cathode. The electrode assembly may be either a jelly-roll type or a stack type. The jelly-roll type electrode assembly may include a winding structure of the anode, the cathode, and the separator interposed therebetween. The stack type electrode assembly may include a plurality of sequentially stacked anodes, a plurality of cathodes, and a plurality of separators interposed therebetween.

[0067] In the stack type electrode assembly, the plurality of anodes and the plurality of cathodes can be arranged in the X direction. In the stack type electrode assembly, the plurality of anodes and the plurality of cathodes can be stacked in the X direction.

[0068] Each of the plurality of anodes of the electrode assembly may include an anode tab. The anode tab of each of the plurality of anodes of the electrode assembly may be short-circuited with the anode terminal (121P). The anode tab of each of the plurality of anodes of the electrode assembly may be welded to the anode terminal (121P).

[0069] Each of the plurality of cathodes of the electrode assembly may include a cathode tab. The cathode tab of each of the plurality of cathodes of the electrode assembly may be short-circuited with the cathode terminal (121N). The cathode tab of each of the plurality of cathodes of the electrode assembly may be welded to the cathode terminal (121N).

[0070] The case (121C) may include an inner resin layer, a metal layer, and an outer resin layer. An adhesive and an anti-corrosion layer may further be provided between the inner resin layer and the metal layer and between the outer resin layer and the metal layer.

[0071] The inner resin layer may have heat-sealing properties and may be referred to as a sealant layer. The inner resin layer may provide sealing of the case (121C). The inner resin layer may include a polyolefin-based resin, such as polypropylene (PP) and polyethylene (PE). The metal layer may include any one of an alloy of iron, carbon, chromium, and manganese, an alloy of iron, chromium, and nickel, and aluminum. The metal layer may be a gas barrier. The metal layer may block the ingress and egress of gas through the case (121C). The outer resin layer may be a surface protection layer. The outer resin layer may include a material having wear resistance and heat resistance, such as a nylon resin.

[0072] The case (121C) may be provided by sealing a single pouch film or by bonding two pouch films. The case (121C) may include a bowl-shaped storage portion formed by a pouch forming process and a terrace surrounding the storage portion. The positive terminal (121P) and the negative terminal (121N) may protrude from the case (121C) in the Y direction. The positive terminal (121P) and the negative terminal (121N) may be spaced apart in the Y direction.

[0073] Hereinafter, the technical concept of the present invention will be described with reference to an example of a bidirectional battery cell (121) in which the positive terminal (121P) and negative terminal (121N) of the battery cell (121) are formed on opposite sides. Those skilled in the art will readily be able to achieve a battery cell assembly comprising unidirectional battery cells based on the description herein.

[0074] The sealing portion of the case (121C) can be fixed to the side of the case (121C) by a folding tape (121A). By applying the folding tape (121A), the sealing portion can be folded to come into contact with the side of the case (121C).

[0075] A plurality of battery cells (121) may constitute a plurality of banks. The battery cells (121) of each of the plurality of banks may be connected in parallel. That is, the positive terminals (121P) of the battery cells (121) of each of the banks may be short-circuited with each other, and the negative terminals (121N) of the battery cells (121) of each of the banks may be short-circuited with each other. According to exemplary embodiments, the positive terminals (121P) of the battery cells (121) of each of the banks may be welded with each other, and the negative terminals (121N) of the battery cells (121) of each of the banks may be welded with each other.

[0076] The negative terminals (121N) of the battery cells (121) of each of the banks can be short-circuited with the positive terminals (121P) of the battery cells (121) of the subsequent bank. The negative terminals (121N) of the battery cells (121) of each of the banks can be welded with the positive terminals (121P) of the battery cells (121) of the subsequent bank.

[0077] The positive terminals (121P) of the battery cells (121) of each of the banks can be short-circuited with the negative terminals (121N) of the battery cells (121) of the preceding bank. The positive terminals (121P) of the battery cells (121) of each of the banks can be welded with the negative terminals (121N) of the battery cells (121) of the preceding bank.

[0078] A plurality of battery cells (121) may be arranged in the X direction. A plurality of pads may be provided between the plurality of battery cells (121). The plurality of pads may horizontally press the plurality of battery cells (121) and prevent or alleviate swelling of the plurality of battery cells (121). The plurality of pads may isolate the plurality of battery cells (121) from each other. According to exemplary embodiments, each of the plurality of pads may include PU (Poly Urethane). According to exemplary embodiments, each of the plurality of pads may include a refractory material such as silicone.

[0079] According to exemplary embodiments, the plurality of pads may be arranged alternately with the plurality of banks. According to exemplary embodiments, one of the plurality of banks may be interposed between adjacent pads, and one of the plurality of pads may be interposed between adjacent banks. According to other exemplary embodiments, two or more banks may be interposed between adjacent pads.

[0080] The first integrated circuit assembly (123) and the second integrated circuit assembly (124) may be spaced apart in the Y direction with a plurality of battery cells (121) therebetween. The first integrated circuit assembly (123) and the second integrated circuit assembly (124) may be electrically connected by FFC assemblies (127). Accordingly, sensing values ​​(e.g., voltage, current, and / or temperature) of the second integrated circuit assembly (124) may be transmitted to the first integrated circuit assembly (123) via the FFC assemblies (127).

[0081] The first integrated circuit assembly (123) may include an insulating frame (123F), an integrated circuit (123I), and sensing plates (123S). The insulating frame (123F) may include an insulating material such as plastic. The insulating frame (123F) may cover the front of a plurality of battery cells (121). The insulating frame (123F) may support the integrated circuit (123I) and the sensing plates (123S).

[0082] The integrated circuit (123I) may be mounted on an insulating frame (123F). The positive terminals (121P) and negative terminals (121N) welded to each other may constitute nodes within the battery cell assembly (120). The integrated circuit (123I) may be configured to measure the voltages of the nodes.

[0083] Each of the plurality of sensing plates (123S) can be coupled to an insulating frame (123S). Each of the plurality of sensing plates (123S) can be in contact with the insulating frame (123S). Each of the plurality of sensing plates (123S) can be fixed to the insulating frame (123S) by a method such as a fitting connection.

[0084] Each of the plurality of sensing plates (123S) may have a patch shape or a pad shape. The plurality of sensing plates (123S) may include a conductive material. The plurality of sensing plates (123S) may be short-circuited to corresponding ones among the positive terminals (121P) and negative terminals (121N) of the plurality of battery cells (121). For example, the plurality of sensing plates (123S) may be short-circuited to the positive terminals (121P) of the battery cells (121) of an odd-numbered bank and the negative terminals (121N) of the battery cells (121) of an even-numbered bank.

[0085] The plurality of sensing plates (123S) may be covered by corresponding ones of the positive terminals (121P) and the negative terminals (121N) of the plurality of battery cells (121). For example, the plurality of sensing plates (123S) may be covered by the positive terminals (121P) of the battery cells (121) of an odd-numbered bank and the negative terminals (121N) of the battery cells (121) of an even-numbered bank. The plurality of sensing plates (123S) may be interposed between the positive terminals (121P) and the negative terminals (121N) and the first insulating frame (123F).

[0086] A plurality of sensing plates (123S) may be in contact with corresponding ones of the positive terminals (121P) and the negative terminals (121N) of the plurality of battery cells (121). For example, a plurality of sensing plates (123S) may be in contact with the positive terminals (121P) of the battery cells (121) of an odd-numbered bank and the negative terminals (121N) of the battery cells (121) of an even-numbered bank.

[0087] A plurality of sensing plates (123S) may be fixed to corresponding ones of the positive terminals (121P) and the negative terminals (121N) of the plurality of battery cells (121). For example, a plurality of sensing plates (123S) may be fixed to the positive terminals (121P) of the battery cells (121) of an odd-numbered bank and the negative terminals (121N) of the battery cells (121) of an even-numbered bank.

[0088] A plurality of sensing plates (123S) may be welded to corresponding ones of the positive terminals (121P) and the negative terminals (121N) of the plurality of battery cells (121). For example, a plurality of sensing plates (123S) may be welded to the positive terminals (121P) of the battery cells (121) of an odd-numbered bank and the negative terminals (121N) of the battery cells (121) of an even-numbered bank.

[0089] Bus bars may be further coupled to the insulating frame (123F). The bus bars may be short-circuited to the positive terminals (121P) of one or more battery cells (121) of the first bank and the negative terminals (121N) of one or more battery cells (121) of the last bank. The bus bars may be welded to the positive terminals (121P) of one or more battery cells (121) of the first bank and the negative terminals (121N) of one or more battery cells (121) of the last bank. The resulting voltages of the plurality of battery cells (121) may be output through the bus bars. The bus bars may be fixed to the insulating frame (123F).

[0090] An insulating cover may be further coupled to the insulating frame (123F). The insulating cover may comprise an insulating material such as plastic. The insulating cover may be fitted to the insulating frame (123F). The insulating cover may cover the integrated circuit (123I) and the sensing plates (123S), thereby protecting the electrical components of the first integrated circuit assembly (123).

[0091] The second integrated circuit assembly (124) may include a second insulating frame (124F), an integrated circuit, and sensing plates. The second integrated circuit assembly (124) is generally similar to the first integrated circuit assembly (123), except that it does not include bus bars.

[0092] Accordingly, the sensing plates of the second integrated circuit assembly (124) are coupled to the second insulating frame (124F), covered by the corresponding positive terminal (121P) and negative terminal (121N), and can be welded to the corresponding positive terminal (121P) and negative terminal (121N). The sensing plates of the second integrated circuit assembly (124) can be interposed between the positive terminals (121P) and negative terminals (121N) and the second insulating frame (124F).

[0093]

[0094] Figure 4 is a perspective view of the first insulating frame (123F) of the battery cell assembly (120).

[0095] Figure 5 is a plan view of the first insulating frame (123F) of the battery cell assembly (120).

[0096] Referring to FIGS. 2 to 5, the first insulating frame (123F) may include a plurality of first terminal supports (123FS) and a plurality of first interposition parts (123FI). The plurality of first terminal supports (123FS) may be arranged in the X direction. The plurality of first interposition parts (123FI) may be arranged in the X direction. The plurality of first terminal supports (123FS) and the plurality of first interposition parts (123FI) may alternate in the X direction. One of the plurality of first interposition parts (123FI) may be interposed between two adjacent first terminal supports (123FS). One of the first terminal supports (123FS) may be interposed between two adjacent first interposition parts (123FI).

[0097] A plurality of first support members (123FS) and a plurality of first intervening members (123FI) may be on a first side (123FS1) of a first insulating frame (123F). The first side (123FS1) may face a plurality of battery cells (121). The first side (123FS1) may face a pouch case (121C) of each of the plurality of battery cells (121). The second side (123FS2) may be opposite to the first side (123FS1). An integrated circuit (123I) may be mounted on the second side (123FS2).

[0098] A plurality of first terminal supports (123FS) may overlap a plurality of positive terminals (121P), a plurality of negative terminals (121N), and a plurality of sensing plates (123S) in the Y direction. A plurality of first terminal supports (123FS) may support a plurality of positive terminals (121P), a plurality of negative terminals (121N), and a plurality of sensing plates (123S).

[0099] Each of the plurality of first terminal supports (123FS) may include a first through-hole (123FT). Each of the plurality of first terminal supports (123FS) may include a first inner side wall (123FW) defining the first through-hole (123FT). The first through-holes (123FT) of each of the plurality of first terminal supports (123FS) may overlap with the plurality of positive terminals (121P) and the plurality of negative terminals (121N) in the Y direction. The first through-holes (123FT) of each of the plurality of first terminal supports (123FS) may overlap with the plurality of sensing plates (123S) in the Y direction.

[0100] According to exemplary embodiments, the first through-holes (123FT) can completely penetrate the corresponding first terminal supports (123FS). According to exemplary embodiments, the height of the first through-hole (123FT) in the Z direction can be substantially the same as the height of each of the plurality of first terminal supports (123FS) in the Z direction. Since each of the plurality of first terminal supports (123FS) does not include a rib, the first inner sidewall (123FW) of each of the plurality of first terminal supports (123FS) defining the first through-hole (123FT) can be solid.

[0101] A plurality of first interposition parts (123FI) may overlap a plurality of ribs (123FR) of a first insulating frame (123F) in the Y direction. The plurality of ribs (123FR) are features having a thin thickness and may be provided by an injection molding process. The plurality of ribs (123FR) may be on a second side (123FS2) of the first insulating frame (123F). The plurality of ribs (123FR) may increase the mechanical strength of the first insulating frame (123F) by preventing deformation of the first insulating frame (123F), while preventing an increase in the weight of the first insulating frame (123F) and a decrease in the cooling speed of the injection molding process of the first insulating frame (123F).

[0102] The first side (123FS1) of the first insulating frame (123F) may be ribless. Each of the plurality of first terminal supports (123FS) and the plurality of first intervening parts (123FI) may not include a rib. Accordingly, even when an impact in the Y direction is transmitted to the battery cell assembly (120), damage to the plurality of battery cells (121) due to the rib can be prevented.

[0103]

[0104] Figure 6 is a perspective view of the second insulating frame (124F) of the battery cell assembly (120).

[0105] Figure 7 is a plan view of the second insulating frame (124F) of the battery cell assembly (120).

[0106] Referring to FIGS. 2, 6, and 7, the second insulating frame (124F) may include a plurality of second terminal supports (124FS) and a plurality of second interposition parts (124FI). The plurality of second terminal supports (124FS) may be arranged in the X direction. The plurality of second interposition parts (124FI) may be arranged in the X direction. The plurality of second terminal supports (124FS) and the plurality of second interposition parts (124FI) may alternate in the X direction. One of the plurality of second interposition parts (124FI) may be interposed between two adjacent second terminal supports (124FS). One of the second terminal supports (124FS) may be interposed between two adjacent second interposition parts (124FI).

[0107] A plurality of second supporting members (124FS) and a plurality of second intervening members (124FI) may be on a first side (124FS1) of a second insulating frame (124F). The first side (124FS1) may face a plurality of battery cells (121). The first side (124FS1) may face a pouch case (121C) of each of the plurality of battery cells (121). The second side (124FS2) may be opposite to the first side (124FS1). An integrated circuit may be mounted on the second side (124FS2).

[0108] A plurality of second terminal supports (124FS) may overlap a plurality of positive terminals (121P), a plurality of negative terminals (121N), and a plurality of sensing plates in the Y direction. A plurality of second terminal supports (124FS) may support a plurality of positive terminals (121P), a plurality of negative terminals (121N), and a plurality of sensing plates.

[0109] Each of the plurality of second terminal supports (124FS) may include a second through hole (124FT). Each of the plurality of second terminal supports (124FS) may include a second inner wall (124FW) defining the second through hole (124FT). The second through holes (124FT) of each of the plurality of second terminal supports (124FS) may overlap with the plurality of positive terminals (121P) and the plurality of negative terminals (121N) in the Y direction. The second through holes (124FT) of each of the plurality of second terminal supports (124FS) may overlap with the plurality of sensing plates in the Y direction.

[0110] According to exemplary embodiments, the second through-holes (124FT) can completely penetrate the corresponding second terminal supports (124FS). According to exemplary embodiments, the height of the second through-hole (124FT) in the Z direction can be substantially the same as the height of each of the plurality of second terminal supports (124FS) in the Z direction. Since each of the plurality of second terminal supports (124FS) does not include a rib, the second inner sidewall (124FW) of each of the plurality of second terminal supports (124FS) defining the second through-hole (124FT) can be solid.

[0111] A plurality of second interposition parts (124FI) may overlap with a plurality of ribs of the second insulating frame (124F) in the Y direction. The plurality of ribs may be on the second side (124FS2) of the second insulating frame (124F). The plurality of ribs may increase the mechanical strength of the second insulating frame (124F) by preventing deformation of the second insulating frame (124F), while preventing an increase in the weight of the second insulating frame (124F) and a decrease in the cooling speed of the injection process of the second insulating frame (124F).

[0112] The first side (124FS1) of the second insulating frame (124F) may be ribless. Each of the plurality of second terminal supports (124FS) and the plurality of second intervening parts (124FI) may not include a rib. Accordingly, even when an impact in the Y direction is transmitted to the battery cell assembly (120), damage to the plurality of battery cells (121) due to the rib can be prevented.

[0113]

[0114] FIG. 8 is a flowchart illustrating a method of providing a battery cell assembly according to exemplary embodiments.

[0115] FIGS. 9 and 10 are perspective views illustrating a method of providing a battery cell assembly according to exemplary embodiments.

[0116] Referring to FIGS. 8, 2, and 3, at P110, a plurality of battery cells (121) and first and second direct circuit assemblies (123, 124) can be assembled. At P110, the plurality of battery cells can be arranged in the X direction. At P110, the positive terminal (121P) and the negative terminal (121N) of the plurality of battery cells (121) can be inserted through slits of the first and second insulating frames (123F, 124F) and coupled to the first and second insulating frames (123F, 124F).

[0117] Referring to FIGS. 8 to 10, at P110, first reinforcing pins (RP1) can be inserted into first through-holes (123FT), and second reinforcing pins (RP2) can be inserted into second through-holes (124FT).

[0118] The first reinforcing pins (RP1) can completely penetrate the first insulating frame (123F). The length of the first reinforcing pins (RP1) in the Z direction may be greater than the height of the first inner wall (123FW, see FIG. 5) defining the first through-holes (123FT) in the Z direction. The length of the first reinforcing pins (RP1) in the Z direction may be greater than the height of the first insulating frame (123F) in the Z direction. The second reinforcing pins (RP2) can completely penetrate the second insulating frame (124F). The length of the second reinforcing pins (RP2) in the Z direction may be greater than the height of the second inner wall (124FW, see FIG. 7) defining the second through-holes (124FT) in the Z direction. The length of the second reinforcing pins (RP2) in the Z direction may be greater than the height of the second insulating frame (124F) in the Z direction.

[0119] Next, referring to FIGS. 2, 3, and 8, at P130, the positive terminals (121P) and the negative terminals (121N) can be welded. The positive terminals (121P) and the negative terminals (121N) can be welded based on either ultrasonic or laser beams. The sensing plates (123S) can be welded together with the positive terminals (121P) and the negative terminals (121N).

[0120] According to exemplary embodiments, even though the second side (123FS2) of the first insulating frame (123F) and the second side (124FS2) of the second insulating frame (123F) are rib-free, the first reinforcing pins (RP1) are inserted into the first through-holes (123FT), and the second reinforcing pins (RP2) are inserted into the second through-holes (124FT), so that the first insulating frame (123F) and the second insulating frame (124F) can stably support the sensing plates (123S), the positive terminals (121P), and the negative terminals (121N) during the welding process.

[0121]

[0122] The present invention has been described in more detail through drawings and examples. However, the configurations described in the drawings or examples described in this specification are merely embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that various equivalents and modified examples may exist as of the time of this application.

Claims

1. A plurality of battery cells arranged in a first direction; and An integrated circuit assembly comprising: a plurality of battery cells; The above integrated circuit assembly includes an insulating frame including an insulating material and an integrated circuit mounted on the insulating frame and configured to be electrically connected to the plurality of battery cells, and The insulating frame includes a first side facing the plurality of battery cells, and A battery cell assembly characterized in that the first side is rib-free.

2. In paragraph 1, The insulating frame includes a plurality of terminal supports arranged on the first side and along the first direction, and A battery cell assembly, wherein each of the plurality of terminal supports includes a through hole.

3. In paragraph 2, Each of the plurality of terminal supports includes an inner wall defining the through hole, and A battery cell assembly, characterized in that the inner wall of each of the plurality of terminal supports is solid.

4. In paragraph 2, Each of the plurality of battery cells includes a positive terminal and a negative terminal, and A battery cell assembly characterized in that each of the plurality of terminal supports overlaps with the positive terminal and the negative terminal of corresponding ones of the plurality of battery cells in a second direction perpendicular to the first direction.

5. In paragraph 4, A battery cell assembly, characterized in that the length of the third direction perpendicular to each of the first and second directions of the through hole is the same as the length of each of the plurality of terminal supports in the third direction.

6. In paragraph 2, A battery cell assembly, characterized in that the insulating frame is on the first side and includes a plurality of interposition portions alternating with the plurality of terminal supports in the first direction.

7. In paragraph 6, The above integrated circuit assembly is mounted on a second side of the insulating frame opposite to the first side, and A battery cell assembly, wherein the insulating frame comprises a plurality of ribs on the second side.

8. In paragraph 7, A battery cell assembly characterized in that the plurality of ribs overlap the plurality of intervening parts.

9. Step of assembling multiple battery cells and integrated circuit assembly; A step of inserting a reinforcing pin into a through hole of an insulating frame of the above integrated circuit assembly, wherein the length of the reinforcing pin is greater than the length of the insulating frame, and A battery cell assembly comprising a step of welding positive terminals and negative terminals of the plurality of battery cells.

10. In paragraph 9 The above plurality of battery cells are arranged in a first direction, and A method for manufacturing a battery cell assembly, characterized in that the reinforcing pin overlaps the positive terminals and the negative terminals of the plurality of battery cells in a second direction perpendicular to the first direction.

11. A plurality of battery cells arranged in a first direction; A first integrated circuit assembly comprising a first insulating frame including an insulating material and a first integrated circuit mounted on the first insulating frame and configured to be electrically connected to the plurality of battery cells; and A second integrated circuit assembly comprising a second insulating frame including an insulating material and a second integrated circuit mounted on the second insulating frame and configured to be electrically connected to the plurality of battery cells, The first insulating frame includes a first side facing the plurality of battery cells and a second side opposite to the first side, The above first side is rib-free, The second insulating frame includes a third side facing the plurality of battery cells and a fourth side opposite to the third side, and A battery cell assembly characterized in that the third side is rib-free.

12. In paragraph 11, The first insulating frame includes a plurality of first terminal supports arranged on the first side and along the first direction, Each of the plurality of first terminal supports includes a first through hole, The second insulating frame comprises a plurality of second terminal supports arranged on the third side and along the first direction, and A battery cell assembly, wherein each of the plurality of second terminal supports includes a second through hole.

13. In paragraph 12, Each of the plurality of first terminal supports includes a first inner wall defining the first through hole, The first inner wall of each of the plurality of first terminal supports is filled, Each of the plurality of second terminal supports includes a second inner wall defining the second through hole, A battery cell assembly, characterized in that the second inner wall of each of the plurality of second terminal supports is filled.

14. In paragraph 12, The first and second integrated circuit assemblies are spaced apart in a second direction perpendicular to the first direction, Each of the plurality of battery cells includes a positive terminal and a negative terminal, and A battery cell assembly characterized in that each of the plurality of first and second terminal supports overlaps with the positive terminal and the negative terminal of corresponding ones of the plurality of battery cells in a second direction perpendicular to the first direction.

15. In paragraph 14, The length of the third direction perpendicular to each of the first and second directions of the first through hole is equal to the length of each of the plurality of first terminal supports in the third direction, and A battery cell assembly, characterized in that the length of the second through hole in the third direction is the same as the length of each of the plurality of second terminal supports in the third direction.

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