Battery-integrated frame and battery-integrated circuit board

Abstract

Disclosed are a battery-integrated frame, a battery-integrated circuit board, a manufacturing method thereof, and an electronic device including same, wherein the frame and the circuit board can be manufactured through a simple manufacturing process compared to an insert molding method and thus are more suitable for mass production. The battery-integrated frame includes a battery stack, a first cover, and a second cover. The battery stack includes a first surface and a second surface opposite to the first surface. The first cover covers the first surface of the battery stack. The second cover covers the second surface of the battery stack. The first cover and the second cover extend to the outside of the battery stack and are bonded to each other.

Description

Battery-integrated frame and battery-integrated circuit board

[0001] The present invention relates to a battery-integrated frame and a battery-integrated circuit board.

[0002] Today, with the advancement of the information age, mobile electronic devices owned by individuals are becoming widely used. These mobile electronic devices inevitably require batteries to operate.

[0003] In the past, primary batteries, such as manganese batteries and alkaline batteries, were mainly used, which were used once and discarded when discharged. However, recently, secondary batteries, which can be recharged after discharge and used repeatedly, are being widely used instead of primary batteries, which are disadvantageous in terms of environmental pollution and cost of discarded batteries.

[0004] These secondary batteries typically consist of a cathode composite, an anode material, an electrolyte, and a separator. Among these, the cathode composite and anode materials are the most crucial components that determine the battery's capacity, lifespan, and charging speed. The cathode composite, as a lithium-ion source, determines the battery's capacity and average voltage, while the anode material determines the charging speed and lifespan.

[0005] Batteries using liquid electrolytes and all-solid-state batteries using solid electrolytes are currently in use. In addition to the advantages of increased energy density, all-solid-state batteries offer the advantages of no volume expansion and no risk of explosion.

[0006] Meanwhile, the fields of Urban Air Mobility (UAM) and robotics face a dire shortage of battery capacity. Consequently, research is underway on battery-integrated frames, which integrate the battery into the housing (or frame) of these devices.

[0007] The problem to be solved by the present invention is to provide a battery-integrated frame and a battery-integrated circuit board that are more suitable for mass production due to a simpler manufacturing process compared to the insert molding method.

[0008] Another problem to be solved by the present invention is to provide an electronic device including such a battery-integrated frame and battery-integrated circuit board.

[0009] Another problem that the present invention seeks to solve is to provide a method for manufacturing such a battery-integrated frame and battery-integrated circuit board.

[0010] An exemplary embodiment of a battery-integrated frame according to the present invention includes a battery stack, a first cover, and a second cover. The battery stack includes a first side and a second side opposite the first side. The first cover covers the first side of the battery stack. The second cover covers the second side of the battery stack. The first cover and the second cover extend to the outside of the battery stack and are joined to each other.

[0011] As one embodiment, the battery stack further includes an opening, and the first cover and the second cover can extend to a portion within the opening and be joined to each other within the opening.

[0012] As an example, the first cover and the second cover may be formed of a glass fiber reinforced polymer (GFRP) or carbon fiber reinforced polymer (CFRP) sheet impregnated with a curing solution.

[0013] At this time, the curing solution may be epoxy.

[0014] As an example, the battery stack may have multiple unit batteries connected in series or parallel.

[0015] As an example, the unit battery may include a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector.

[0016] In one embodiment, the battery stack further includes an opening, and the first cover and the second cover extend to a portion within the opening and are joined to each other within the opening, and the openings of the positive electrode collector, the positive electrode material, the negative electrode material, and the negative electrode collector are larger than the openings of the separator, so that a portion of the separator can be exposed inside the openings of the positive electrode collector, the positive electrode material, the negative electrode material, and the negative electrode collector.

[0017] As one embodiment, the positive electrode current collector may extend to a first side based on the positive electrode material, the separator, and the negative electrode material, and the negative electrode current collector may extend to a second side opposite to the first side.

[0018] As one embodiment, the battery-integrated frame further includes a first metal pipe and a second metal pipe, wherein the first metal pipe is electrically connected to the positive electrode current collector, the second metal pipe is electrically connected to the negative electrode current collector, and the first metal pipe and the second metal pipe can be exposed to the outside of the first cover or the second cover.

[0019] At this time, the exposed ends of the first metal pipe and the second metal pipe may be blocked.

[0020] As one embodiment, the device includes a positive terminal and a negative terminal, which are respectively connected to the positive current collector and the negative current collector, and are connected to the outside of the first cover or the second cover, and when viewed in plan, one of the positive terminal and the negative terminal may be arranged at the same position, and the other may be arranged at a different position.

[0021] As an example, the battery stack may further include an insulating layer for insulation between the unit batteries and the first cover and the second cover.

[0022]

[0023] A battery-integrated circuit board according to an exemplary embodiment of the present invention includes a battery stack, a first cover, a second cover, and a first circuit layer. The battery stack includes a first surface and a second surface opposite the first surface. The first cover covers the first surface of the battery stack. The second cover covers the second surface of the battery stack. The first circuit layer is formed on an outer surface of the first cover. At this time, the first cover and the second cover extend to the outer side of the battery stack and are joined to each other.

[0024] As one embodiment, the battery stack further includes an opening, and the first cover and the second cover can extend to a portion within the opening and be joined to each other within the opening.

[0025] As one embodiment, the battery-integrated circuit board further includes a second circuit layer formed on the outer surface of the second cover, and the first circuit layer and the second circuit layer can be electrically connected through the opening.

[0026] As an example, the battery stack may have multiple unit batteries connected in series or parallel.

[0027] As an example, the unit battery may include a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector.

[0028] In one embodiment, the battery stack further includes an opening, and the first cover and the second cover extend to a portion within the opening and are joined to each other within the opening, and the openings of the positive electrode collector, the positive electrode material, the negative electrode material, and the negative electrode collector are larger than the openings of the separator, so that a portion of the separator can be exposed inside the openings of the positive electrode collector, the positive electrode material, the negative electrode material, and the negative electrode collector.

[0029] As one embodiment, the positive electrode current collector may extend to a first side based on the positive electrode material, the separator, and the negative electrode material, and the negative electrode current collector may extend to a second side opposite to the first side.

[0030] As an example, the battery stack may further include an insulating layer for insulation between the unit batteries and the first cover and the second cover.

[0031]

[0032] An electronic device according to an exemplary embodiment of the present invention includes any of the battery-integrated frames or battery-integrated circuit boards mentioned above. Such an electronic device may be any device requiring a battery, such as a drone, a smartphone, or the like, as well as the robot exemplified in FIG. 1.

[0033]

[0034] A method for manufacturing a battery-integrated frame according to an exemplary embodiment of the present invention includes the steps of forming a battery laminate, and arranging a first cover sheet and a second cover sheet, each having an area extending beyond an outer end of the battery laminate, on a first side and a second side of the battery laminate, respectively, and bonding the first cover sheet and the second cover sheet to each other.

[0035] As one embodiment, the method for manufacturing such a battery-integrated frame may further include, after forming a battery laminate, a step of forming an opening in the battery laminate, and, after the step of bonding the first cover sheet and the second cover sheet to each other, a step of forming a through hole smaller than the opening in the first cover sheet and the second cover sheet bonded to each other within the opening.

[0036] As an example, in the step of forming a battery stack, the battery stack may include a plurality of unit batteries connected in series or in parallel, and the unit battery may include a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector, and an opening formed in the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector may be larger than an opening formed in the separator, such that a portion of the separator may be exposed inside the openings of the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector.

[0037] As one embodiment, the method for manufacturing a battery-integrated frame may further include, after the step of forming the battery laminate, a step of forming the battery laminate.

[0038] As one embodiment, the method for manufacturing such a battery-integrated frame may further include, after the step of bonding the first cover sheet and the second cover sheet to each other, the step of injecting an electrolyte into the interior between the first cover sheet and the second cover sheet.

[0039] At this time, the electrolyte injection can be performed through an electrolyte injection port formed in the first cover sheet or the second cover sheet.

[0040] As one embodiment, the electrolyte inlet includes a first metal pipe electrically connected to the positive electrode current collector and a second metal pipe electrically connected to the negative electrode current collector, and the electrolyte may be injected through one of the first metal pipe and the second metal pipe, sucked through the other, and after the electrolyte injection is completed, the first metal pipe and the second metal pipe may be sealed.

[0041] Meanwhile, the first cover sheet and the second cover sheet may be formed of a glass fiber reinforced polymer (GFRP) or carbon fiber reinforced polymer (CFRP) sheet impregnated with a curing solution.

[0042] At this time, the curing solution may be epoxy.

[0043]

[0044] A method for manufacturing a battery-integrated circuit board according to an exemplary embodiment of the present invention comprises the steps of forming a battery laminate, and arranging a first cover sheet and a second cover sheet, each having an area extending beyond an outer end of the battery laminate, on a first side and a second side of the battery laminate, respectively, and bonding the first cover sheet and the second cover sheet to each other.

[0045] As one embodiment, the method for manufacturing a battery-integrated circuit board may further include, after forming a battery laminate, a step of forming an opening in the battery laminate, and, after the step of bonding the first cover sheet and the second cover sheet to each other, a step of forming a through hole smaller than the opening in the first cover sheet and the second cover sheet bonded to each other within the opening.

[0046] As an example, in the step of forming a battery stack, the battery stack may include a plurality of unit batteries connected in series or in parallel, and the unit battery may include a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector, and an opening formed in the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector may be larger than an opening formed in the separator, such that a portion of the separator may be exposed inside the openings of the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector.

[0047] As one embodiment, a method for manufacturing a battery-integrated circuit board may further include, after the step of forming a battery laminate, a step of forming the battery laminate.

[0048] As an example, the first cover sheet may have a first circuit layer formed thereon.

[0049] In addition, a second circuit layer is formed on the second cover sheet, and the method for manufacturing a battery-integrated circuit board may further include a step of electrically connecting the first circuit layer and the second circuit layer through the through hole.

[0050] As one embodiment, a method for manufacturing a battery-integrated circuit board may further include, after the step of bonding the first cover sheet and the second cover sheet to each other, a step of injecting an electrolyte into the interior between the first cover sheet and the second cover sheet.

[0051] At this time, the electrolyte injection can be performed through an electrolyte injection port formed in the first cover sheet or the second cover sheet.

[0052] As one embodiment, a method for manufacturing a battery-integrated circuit board may further include, after the step of bonding the first cover sheet and the second cover sheet to each other, a step of forming a first circuit layer on the first cover sheet.

[0053] As one embodiment, a method for manufacturing a battery-integrated circuit board may further include, after the step of forming a first circuit layer on the first cover sheet, a step of forming a second circuit layer on the second cover sheet, and a step of electrically connecting the first circuit layer and the second circuit layer through the through hole.

[0054] As an example, after the step of bonding the first cover sheet and the second cover sheet to each other, or after the step of electrically connecting the first circuit layer and the second circuit layer through the through hole, the method may further include a step of injecting an electrolyte into the interior between the first cover sheet and the second cover sheet.

[0055] At this time, the electrolyte injection can be performed through an electrolyte injection port formed in the first cover sheet or the second cover sheet.

[0056] In this way, the battery-integrated frame according to the present invention is manufactured by placing cover sheets on the upper and lower parts of the battery stack and attaching the cover sheets, and thus, compared to the insert molding method in which the battery stack (BA) is placed inside a mold and formed by injecting resin, the manufacturing process is simpler and thus more suitable for mass production.

[0057] In addition, the opening can perform a function of allowing another device to be attached to the battery-integrated frame, or a screw or the like to be inserted when the battery-integrated frame is attached to another device, and can also absorb volume expansion during charging and discharging of the battery stack.

[0058] When the above unit batteries are connected in series with each other, the voltage can be increased, and when connected in parallel, the capacity of the battery stack can be increased.

[0059] By reducing the size of the opening of the separator so that a portion of the separator is exposed inside the opening of the positive electrode material, the negative electrode material, and the negative electrode current collector, a short circuit between the positive electrode current collector or the positive electrode material and the negative electrode material or the negative electrode current collector can be more reliably prevented.

[0060] Figure 1 is a conceptual diagram illustrating a robot to which a battery-integrated frame according to the present invention is applied.

[0061] Fig. 2 is a cross-sectional view of a battery-integrated frame applied to the robot illustrated in Fig. 1.

[0062] Figure 3 is another embodiment of a battery-integrated frame.

[0063] Figure 4 is an enlarged view of area A shown in Figures 2 and 3.

[0064] FIG. 5 is a cross-sectional view illustrating one embodiment of the battery stack illustrated in FIG. 2 or FIG. 3.

[0065] FIG. 6 is an embodiment showing a terminal portion of the battery-integrated frame illustrated in FIG. 2 or FIG. 3.

[0066] FIG. 7 is another embodiment showing a terminal portion of the battery-integrated frame illustrated in FIG. 2 or FIG. 3.

[0067] Fig. 8 is a cross-sectional view illustrating a battery-integrated circuit board according to an exemplary embodiment of the present invention.

[0068] FIG. 9 is a flowchart illustrating a method for manufacturing a battery-integrated frame according to an exemplary embodiment of the present invention.

[0069] Fig. 10 is a conceptual diagram illustrating step S130 illustrated in Fig. 9.

[0070] Figure 11 is a conceptual diagram illustrating step S140 illustrated in Figure 9.

[0071] Fig. 12 is a conceptual diagram illustrating a battery opening area after step S140 illustrated in Fig. 9.

[0072] FIG. 13 is a conceptual diagram illustrating the battery opening area after step S150 illustrated in FIG. 9.

[0073] Fig. 14 is a conceptual diagram illustrating an electrolyte injection port for performing step S160 illustrated in Fig. 9.

[0074] Fig. 15 is a flowchart illustrating a method for manufacturing a battery-integrated frame according to another exemplary embodiment of the present invention.

[0075] FIG. 16 is a schematic cross-sectional view illustrating a battery stack formed as a result of step S210 of FIG. 15.

[0076] Fig. 17 is a schematic plan view of the battery stack illustrated in Fig. 16.

[0077] Fig. 18 is a schematic cross-sectional view of a battery-integrated frame according to an exemplary embodiment of the present invention.

[0078] Fig. 19 is a side view showing an example of stacking and connecting battery-integrated frames in series according to the present invention.

[0079] Fig. 20 is a plan view showing the battery-integrated frames illustrated in Fig. 19 in a separated state.

[0080] The present invention is susceptible to various modifications and takes various forms. Specific embodiments are illustrated in the drawings and described in detail in the text. However, this is not intended to limit the present invention to a specific disclosed form, but rather to encompass all modifications, equivalents, and alternatives falling within the spirit and technical scope of the present invention. Throughout the description of each drawing, similar reference numerals have been used to designate similar components. In the accompanying drawings, the dimensions of structures may be exaggerated to enhance clarity of the present invention.

[0081] While terms like "first" and "second" may be used to describe various components, these components should not be limited by these terms. These terms are used solely to distinguish one component from another. For example, without departing from the scope of the present invention, a first component could be referred to as a "second component," and similarly, a second component could also be referred to as a "first component."

[0082] The terminology used in this application is only used to describe specific embodiments and is not intended to limit the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, it should be understood that the terms "comprise" or "have" are intended to specify the presence of a feature, number, step, operation, component, part, or combination thereof described in the specification, but do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof. In addition, the meaning of A and B being "connected" or "coupled" includes a case where, in addition to A and B being directly connected or coupled, another component C is included between A and B so that A and B are connected or coupled.

[0083] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by a person of ordinary skill in the art to which this invention pertains. Terms defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and will not be construed in an idealized or overly formal sense unless explicitly defined herein. Furthermore, in the claims for method inventions, the order of the steps may be interchanged, unless the order of the steps is explicitly stated.

[0084] Additionally, the configurations individually described in each embodiment may also be applied in other embodiments.

[0085] Fig. 1 is a conceptual diagram illustrating a robot to which a battery-integrated frame according to the present invention is applied, and Fig. 2 is a cross-sectional view of the battery-integrated frame applied to the robot illustrated in Fig. 1. Fig. 3 is another embodiment of the battery-integrated frame, and Fig. 4 is an enlarged view of area A illustrated in Figs. 2 and 3.

[0086] Referring to FIGS. 1 to 4, a battery-integrated frame (BF) according to an exemplary embodiment of the present invention can be formed integrally with the frame (or housing) of an electronic device requiring power for operation, such as a robot (PR) or drone. In this way, when the battery is formed integrally with the frame, a separate space for battery placement is not required, enabling an efficient configuration.

[0087] The above battery integrated frame (BF) includes a battery stack (BA), a first cover (FC), and a second cover (SC).

[0088] The above battery stack (BA) includes a first side and a second side opposite the first side. The battery stack (BA) is a secondary battery formed to be capable of charging and discharging, and may be applied to a nickel-metal hydride (Ni-MH) battery, a lithium ion battery (Li-ion), a lithium ion polymer battery (Li-ion polymer), etc. These are merely examples, and it is obvious to those skilled in the art that the battery stack (BA) may be applied to other secondary batteries besides the above-mentioned ones.

[0089] The first cover (FC) covers the first surface of the battery stack (BA). The second cover (SC) covers the second surface of the battery stack (BA). At this time, the first cover (FC) and the second cover (SC) extend to the outside of the battery stack (BA) and are joined to each other. That is, as illustrated in Fig. 4, the first cover (FC) and the second cover (SC) extend to the outside of the end of the battery stack (BA) and are joined to each other at the joining portion (CR).

[0090] As an example, the first cover (FC) and the second cover (SC) may be formed of a glass fiber reinforced polymer (GFRP) or carbon fiber reinforced polymer (CFRP) sheet impregnated with a curing agent. In this case, the curing agent may be epoxy.

[0091] Hereinafter, as will be described in more detail in the manufacturing method, the battery-integrated frame according to the present invention is manufactured by placing cover sheets on the upper and lower parts of the battery laminate and attaching the cover sheets, so that the manufacturing process is simpler than the insert molding method in which the battery laminate (BA) is placed inside a mold and formed by injecting resin, and thus is more suitable for mass production.

[0092] As an example, the battery stack (BA) further includes an opening (OP), and the first cover (FC) and the second cover (SC) cover a portion of the opening (OP) and can be joined to each other within the opening (OP). This opening (OP) can perform a function of allowing another device to be attached to the battery integrated frame (BF) or inserting a screw or the like when the battery integrated frame (BF) is attached to another device, and can also absorb volume expansion during charging and discharging of the battery stack (BA).

[0093]

[0094] FIG. 5 is a cross-sectional view illustrating one embodiment of the battery stack illustrated in FIG. 2 or FIG. 3.

[0095] Referring to FIG. 5, as an example, the battery stack (BA) may include a plurality of unit batteries connected in series or parallel. When the unit batteries are connected in series, the voltage can be increased, and when connected in parallel, the capacity of the battery stack (BA) can be increased.

[0096] As an example, the unit battery may include a positive electrode current collector (110), a positive electrode material (120), a separator (130), a negative electrode material (140), and a negative electrode current collector (150).

[0097] The positive electrode current collector (110) may be formed, for example, of an aluminum (Al) thin film, and the negative electrode current collector (150) may be formed, for example, of a copper (Cu) thin film.

[0098] For example, if the unit battery is a lithium-sulfur battery, the cathode material (120) may be a mixture of sulfur, a binder, and a conductive agent. The cathode material (120) may be formed by mixing sulfur, a binder, a conductive agent, and an organic solvent to form a slurry, applying the slurry to the cathode current collector (110), and then blowing hot air at 90 to 120°C to evaporate the organic solvent. At this time, the binder may be SBR, NR, NBR, PVDF, a thermoplastic resin, a silane, or the like. In addition, the organic solvent may be toluene, alcohol, NMP, or the like.

[0099] The above separator (130) may be a conventional separator. In addition, lithium metal may be applied as the negative electrode material (140).

[0100] The unit battery described above is an example, and other commonly used secondary batteries may also be applied.

[0101] Meanwhile, the battery stack (BA) illustrated in FIG. 5 illustrates an example in which unit batteries are connected in parallel. That is, a positive electrode material (120), a separator (130), a negative electrode material (140), and a negative electrode collector (150) are sequentially stacked on the lower surface of the positive electrode collector (110) at the very top, so that the positive electrode is arranged above and the negative electrode is arranged below, and a negative electrode material (140), a separator (130), a positive electrode material (120), and a positive electrode collector (110) are sequentially stacked on the lower surface of the negative electrode collector (150), so that the positive electrode is arranged below and the negative electrode is arranged above.

[0102] In this case, when the positive current collectors (110) are connected to each other and the negative current collectors (150) are connected to each other, each unit battery has a configuration in which it is connected in parallel.

[0103] In this way, in order to connect the positive current collectors (110) to each other and the negative current collectors (150) to each other, the positive current collector (110) has a protrusion (110P) in the first side (right side in the drawing) direction, and the negative current collector (150) has a protrusion (150P) in the second side (left side in the drawing) direction.

[0104] That is, the positive electrode current collector (110) may extend to a first side (right side in the drawing) based on the positive electrode material (120), the separator (130), and the negative electrode material (140), and the negative electrode current collector (150) may extend to a second side (left side in the drawing) opposite to the first side.

[0105] In the drawing, for convenience, the positive current collectors (110) are shown as being connected to each other, and the negative current collectors (150) are shown as being connected to each other, but the protrusions (110P) of the extended positive current collectors (110) and the protrusions (150P) of the negative current collectors (150) are connected to each other.

[0106] As an example, the battery stack (BA) may further include an insulating layer (200) for insulating the unit batteries from the first cover (FC) and the second cover (SC). For example, the insulating layer (200) may be formed of polyimide (PI) or prepreg. The insulating layer (200) may prevent short circuits with carbon fiber or a conductive material constituting the first or second cover.

[0107]

[0108] FIG. 6 is an embodiment showing a terminal portion of the battery-integrated frame shown in FIG. 2 or FIG. 3, and FIG. 7 is another embodiment showing a terminal portion of the battery-integrated frame shown in FIG. 2 or FIG. 3.

[0109] Referring to Fig. 6, the positive terminal (PT) and the negative terminal (NT) for electrical connection between the battery-integrated frame (BF) and the electronic devices inside the frame may be exposed on both sides of the battery-integrated frame (BF), respectively. Alternatively, the positive terminal (PT) and the negative terminal (NT) may be exposed on one side of the battery-integrated frame (BF).

[0110] Alternatively, as illustrated in FIG. 7, the positive terminal (PT) and negative terminal (NT) may be exposed through the first side or the second side of the battery integrated frame (BF).

[0111]

[0112] Fig. 8 is a cross-sectional view illustrating a battery-integrated circuit board according to an exemplary embodiment of the present invention. The battery-integrated circuit board illustrated in Fig. 8 is substantially identical to the previously described battery-integrated frame, except that the circuit layer is formed on the first cover and / or the second cover. Therefore, it will be apparent to those skilled in the art that the aforementioned principles can also be applied to parts not described below.

[0113] Referring to FIG. 8, a battery-integrated circuit board according to an exemplary embodiment of the present invention includes a battery stack (BA), a first cover (FC), a second cover (SC), and a first circuit layer (FCL).

[0114] The above battery stack (BA) includes a first side and a second side opposite to the first side.

[0115] The first cover (FC) covers the first surface of the battery stack (BA). The second cover (SC) covers the second surface of the battery stack (BA).

[0116] The first circuit layer (FCL) is formed on the outer surface of the first cover (FC). At this time, the first cover (FC) and the second cover (SC) extend to the outer side of the battery stack (BA) and are joined to each other.

[0117] As an example, the battery stack (BA) further includes an opening (OP), and the first cover (FC) and the second cover (SC) extend to a portion within the opening (OP) and can be joined to each other within the opening (OP).

[0118] As an example, the battery-integrated circuit board further includes a second circuit layer (SCL) formed on the outer surface of the second cover (SC), and the first circuit layer (FCL) and the second circuit layer (SCL) can be electrically connected through the opening (OP).

[0119] As an example, the battery stack (BA) may have multiple unit batteries connected in series or parallel.

[0120] As described above, the unit battery may include a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector.

[0121] In addition, the positive electrode current collector may extend to a first side based on the positive electrode material, the separator, and the negative electrode material, and the negative electrode current collector may extend to a second side opposite to the first side.

[0122] Additionally, the battery stack (BA) may further include an insulating layer for insulation between the unit batteries and the first cover (FC) and the second cover (SC).

[0123]

[0124] An electronic device according to an exemplary embodiment of the present invention includes any of the battery-integrated frame (BF) or battery-integrated circuit boards mentioned above. Such an electronic device may be any device requiring a battery, such as a drone, smartphone, or the like, as well as the robot exemplified in FIG. 1.

[0125]

[0126] FIG. 9 is a flowchart illustrating a method for manufacturing a battery-integrated frame according to an exemplary embodiment of the present invention.

[0127] Referring to FIG. 9, according to a method for manufacturing a battery-integrated frame according to an exemplary embodiment of the present invention, a battery stack is first formed (step S110). As previously described, the battery stack may be a conventional secondary battery requiring an electrolyte, or an all-solid-state battery may be applied. For example, such a battery stack may be formed to have the stacking structure of FIG. 5.

[0128] Thereafter, an opening is formed in the battery stack (step S120). A plurality of openings may be formed. The formation of such openings is optional and is performed when necessary, and the openings may not be formed.

[0129] Thereafter, the battery stack is formed (step S130). This forming of the stack is also optional. That is, if the battery-integrated frame is flat, as shown in FIG. 3, the forming process can be omitted, and even if it is curved, as shown in FIG. 2, forming can be performed at once after bonding the first and second cover sheets. However, in the present invention, as shown in FIG. 10, the first and second cover sheets are bonded after the battery stack is formed.

[0130] Fig. 10 is a conceptual diagram illustrating step S130 illustrated in Fig. 9.

[0131] Referring to Fig. 10, a battery stack (BA) is placed between a first upper mold (UM1) and a first lower mold (LM2), and the first upper mold (UM1) and the first lower mold (LM2) are pressed against each other to form the battery stack (BA). In this way, when the battery stack (BA) is formed first, workability can be improved. More specifically, when the second cover sheet, the battery stack, and the first cover sheet are sequentially placed on the first lower mold (LM1) and forming is performed at once, the positions of the battery stack, etc. may be misaligned, resulting in a defect. However, when only the battery stack is formed first, the battery stack fixes the second cover sheet at the bottom and presses the first cover sheet at the top, so this problem is solved.

[0132] Thereafter, a cover part is formed on the battery stack (step S140). More specifically, a first cover sheet and a second cover sheet having an area extending beyond an outer end of the battery stack are respectively placed on the first side and the second side of the battery stack, and the first cover sheet and the second cover sheet are bonded to each other. In one embodiment, the first cover sheet and the second cover sheet may be formed of a glass fiber reinforced polymer (GFRP) or carbon fiber reinforced polymer (CFRP) sheet impregnated with a curing agent.

[0133] At this time, the curing solution may be epoxy.

[0134] Figure 11 is a conceptual diagram illustrating step S140 illustrated in Figure 9.

[0135] A second cover sheet (SC), a battery stack (BA), and a first cover sheet (FC) are sequentially placed on a second lower mold (LM2), and the first upper mold (UM1) is pressed to bond the first and second cover sheets (FC, SC). In Fig. 11, for convenience, the first cover sheet and the second cover sheet (FC, SC) are illustrated to correspond to one BA, but they may be of a large size to correspond to multiple battery stacks (BA), and may be individually separated after bonding is completed.

[0136] Thereafter, within the opening, a through hole smaller than the opening is formed in the first cover sheet and the second cover sheet that are joined to each other (step S150).

[0137] FIG. 12 is a conceptual diagram illustrating a battery opening area after step S140 illustrated in FIG. 9, and FIG. 13 is a conceptual diagram illustrating a battery opening area after step S150 illustrated in FIG. 9.

[0138] Referring to FIG. 12, in an opening area having a first diameter (D1), the first cover sheet (FC) and the second cover sheet (SC) are formed by being joined to each other, thereby forming a through hole having a second diameter (D2) smaller than the first diameter (D1), as shown in FIG. 13.

[0139]

[0140] As an example, the method for manufacturing such a battery-integrated frame may further include a step (S160) of injecting an electrolyte into the interior between the first cover sheet and the second cover sheet. This electrolyte may be omitted if the battery stack is an all-solid-state battery.

[0141] At this time, the electrolyte injection can be performed through the electrolyte injection port (IH) shown in Fig. 14 formed on the first cover sheet or the second cover sheet. For convenience, only one electrolyte injection port (IH) is shown, but another hole can be opened on the opposite side so that suction can be performed through the other hole, allowing the electrolyte to be injected smoothly. This electrolyte can penetrate the separator.

[0142] In addition, the electrolyte injection is performed after the first cover sheet (FC) and the second cover sheet (SC) are bonded, but since bonding the first cover sheet (FC) and the second cover sheet (SC) is a thermal process, if the electrolyte is injected before bonding the first cover sheet (FC) and the second cover sheet (SC), expansion such as evaporation of the electrolyte or deterioration of the electrolyte may occur during the thermal process. Accordingly, the electrolyte injection process is performed after bonding the first cover sheet (FC) and the second cover sheet (SC).

[0143]

[0144] Fig. 15 is a flowchart illustrating a method for manufacturing a battery-integrated frame according to another exemplary embodiment of the present invention. The method for manufacturing a battery-integrated frame according to another exemplary embodiment of the present invention illustrated in Fig. 15 is substantially the same as the method illustrated in Fig. 9 except that step S210 is performed instead of steps S110 and S120. Therefore, description of steps in the manufacturing method that are identical or similar will be omitted.

[0145] In the method illustrated in FIG. 9, after forming a battery stack, the battery stack is punched to form an opening at once, whereas in the method illustrated in FIG. 15, a battery stack with an opening formed is formed (step S210). In this case, the size of the opening formed between each layer constituting the battery stack can be adjusted differently. This will be described in more detail with reference to FIGS. 16 and 17 below.

[0146]

[0147] Fig. 16 is a schematic cross-sectional view illustrating a battery stack formed as a result of step S210 of Fig. 15, and Fig. 17 is a schematic plan view of the battery stack illustrated in Fig. 16. In Figs. 16 and 17, only one unit battery is illustrated for convenience, and it is obvious to those skilled in the art that a plurality of unit batteries may be provided, such as the battery stack (BA) of Fig. 5.

[0148] Referring to FIGS. 16 and 17, the battery stack (BA) includes a positive electrode current collector (110), a positive electrode material (120), a separator (130), a negative electrode material (140), and a negative electrode current collector (150), and the size (D3) of the opening of the positive electrode current collector (110), the positive electrode material (120), the negative electrode material (140), and the negative electrode current collector (150) is larger than the size (D1) of the opening of the separator (130), so that a part of the separator (130) may be exposed inside the opening of the positive electrode current collector (110), the positive electrode material (120), the negative electrode material (140), and the negative electrode current collector (150).

[0149] In this way, when the size (D1) of the opening of the separator (130) is made small so that a part of the separator (130) is exposed inside the opening of the positive electrode material (120), the negative electrode material (140), and the negative electrode current collector (150), a short circuit between the positive electrode current collector (110) or the positive electrode material (120) and the negative electrode material (140) or the negative electrode current collector (150) can be more reliably prevented.

[0150]

[0151] The method for manufacturing a battery-integrated circuit board according to the present invention is substantially the same as the method for manufacturing a battery-integrated frame, so redundant descriptions are omitted. However, since the battery-integrated circuit board has circuit layers formed on the first cover and the second cover, the circuit layers may be formed before attaching the first cover and the second cover. Alternatively, if the first cover and the second cover are not formed, the circuit layers may be formed later. In this case, the circuit layers may be formed before or after electrolyte injection (step S160).

[0152]

[0153] Fig. 18 is a schematic cross-sectional view of a battery-integrated frame according to an exemplary embodiment of the present invention.

[0154] Referring to FIG. 18, the battery-integrated frame may further include a first metal pipe (MP1) and a second metal pipe (MP2).

[0155] The first metal pipe (MP1) is electrically connected to the positive electrode current collector (110), the second metal pipe (MP2) is electrically connected to the negative electrode current collector (150), and the first metal pipe (MP1) and the second metal pipe (MP2) can be exposed to the outside of the first cover (FC) or the second cover (SC).

[0156] In the manufacturing process, in Fig. 14, a separate electrolyte injection port (IH) is provided for electrolyte injection, but in the present embodiment disclosed in Fig. 18, a first metal pipe (MP1) and a second metal pipe (MP2) are provided, and electrolyte can be injected through these.

[0157] In more detail, the electrolyte may be injected through one of the first metal pipe (MP1) and the second metal pipe (MP2), sucked through the other, and after the electrolyte injection is completed, the first metal pipe (MP1) and the second metal pipe (MP2) may be sealed. Accordingly, the exposed ends of the first metal pipe (MP1) and the second metal pipe (MP2) of the battery-integrated frame manufactured in this manner may be blocked.

[0158]

[0159] Fig. 19 is a side view showing an example of stacking and serially connecting battery-integrated frames according to the present invention, and Fig. 20 is a plan view showing the battery-integrated frames shown in Fig. 19 in a separated state.

[0160] In Fig. 19, the battery-integrated frames according to the present invention are stacked and connected in series. That is, the first to third battery-integrated frames (BF1, BF2, BF3) are stacked, the negative terminal (NT) of the first battery-integrated frame (BF1) and the positive terminal (PT) of the second battery-integrated frame (BF2) are connected, and the negative terminal (NT) of the second battery-integrated frame (BF2) and the positive terminal (PT) of the third battery-integrated frame (BF3) are connected, so that the first to third battery-integrated frames (BF1, BF2, BF3) can be connected in series.

[0161] Meanwhile, in order to prevent short circuit during stacking in this manner, when viewed from a planar perspective, one of the positive terminal (PT) and the negative terminal (NT) may be placed at the same position, and the other may be placed at a different position.

[0162] As illustrated in FIG. 20, the two battery-integrated frames adjacently stacked with respect to the plane terminal positions of the first to third battery-integrated frames (BF1, BF2, BF3) are arranged such that one of the positive terminal (PT) and the negative terminal (NT) is arranged at the same position, and the other is arranged at a different position. In more detail, the negative terminal (NT) of the first battery-integrated frame (BF1) and the positive terminal (PT) of the second battery-integrated frame (BF2) are arranged at the same position, and the positive terminal (PT) of the first battery-integrated frame (BF1) and the negative terminal (NT) of the second battery-integrated frame (BF2) are arranged at different positions. Similarly, the negative terminal (NT) of the second battery-integrated frame (BF2) and the positive terminal (PT) of the third battery-integrated frame (BF3) are arranged at the same position, and the positive terminal (PT) of the second battery-integrated frame (BF2) and the negative terminal (NT) of the third battery-integrated frame (BF3) are arranged at different positions.

[0163]

[0164] In this way, the battery-integrated frame according to the present invention is manufactured by placing cover sheets on the upper and lower parts of the battery stack and attaching the cover sheets, and thus, compared to the insert molding method in which the battery stack (BA) is placed inside a mold and formed by injecting resin, the manufacturing process is simpler and thus more suitable for mass production.

[0165]

[0166] Although the detailed description of the present invention described above has been described with reference to preferred embodiments of the present invention, it will be understood by those skilled in the art or having ordinary knowledge in the art that various modifications and changes can be made to the present invention without departing from the spirit and technical scope of the present invention as set forth in the claims to be described later.

Claims

1. A battery stack comprising a first side and a second side opposite to the first side: A first cover covering the first surface of the battery stack; and A second cover covering the second surface of the battery stack; Including, The first cover and the second cover are a battery-integrated frame that extend to the outside of the battery stack and are joined to each other.

2. In paragraph 1 The above battery stack further includes an opening, A battery-integrated frame, characterized in that the first cover and the second cover extend to a portion within the opening and are joined to each other within the opening.

3. In paragraph 1, The above first cover and the above second cover A battery-integrated frame characterized by being formed of a glass fiber reinforced polymer (GFRP) or carbon fiber reinforced polymer (CFRP) sheet probed by a curing solution.

4. In paragraph 3, A battery-integrated frame characterized in that the above-mentioned hardening agent is epoxy.

5. In paragraph 1, The above battery stack is, A battery-integrated frame characterized by a plurality of unit batteries connected in series or parallel.

6. In paragraph 5, The above unit battery is, A battery integrated frame comprising a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector.

7. In paragraph 6, The above battery stack further includes an opening, The first cover and the second cover extend to a portion within the opening and are joined to each other within the opening, A battery integrated frame characterized in that the openings of the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector are larger than the openings of the separator, so that a portion of the separator is exposed inside the openings of the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector.

8. In paragraph 6, The positive electrode current collector extends to the first side based on the positive electrode material, the separator, and the negative electrode material, A battery-integrated frame, characterized in that the negative electrode current collector extends to a second side opposite to the first side.

9. In paragraph 6, A first metal pipe electrically connected to the positive electrode collector; and A second metal pipe electrically connected to the negative electrode collector; A battery-integrated frame further comprising the first metal pipe and the second metal pipe, characterized in that they are exposed to the outside of the first cover or the second cover.

10. In paragraph 9, A battery-integrated frame, characterized in that the exposed ends of the first metal pipe and the second metal pipe are blocked.

11. In paragraph 6, It includes a positive terminal and a negative terminal connected to the positive current collector and the negative current collector, respectively, and connected to the outside of the first cover or the second cover, A battery-integrated frame characterized in that, when viewed from a planar perspective, one of the positive terminal and the negative terminal is positioned at the same position, and the other is positioned at a different position.

12. In paragraph 5, A battery-integrated frame characterized in that the battery stack further includes an insulating layer for insulation between the unit batteries and the first cover and the second cover.

13. A battery stack comprising a first side and a second side opposite to the first side: A first cover covering the first surface of the battery stack; and A second cover covering the second surface of the battery stack; A first circuit layer formed on the outer surface of the first cover; Including, The first cover and the second cover are a battery-integrated circuit board that extends to the outside of the battery stack and are joined to each other.

14. In paragraph 13, The above battery stack further includes an opening, A battery-integrated circuit board, characterized in that the first cover and the second cover extend to a portion within the opening and are joined to each other within the opening.

15. In paragraph 14, A second circuit layer formed on the outer surface of the second cover; Including more, A battery-integrated circuit board, characterized in that the first circuit layer and the second circuit layer are electrically connected through the opening.

16. In paragraph 13, The above battery stack is, A battery-integrated circuit board characterized by a plurality of unit batteries connected in series or parallel.

17. In paragraph 16, The above unit battery is, A battery integrated circuit board comprising a positive electrode current collector, a positive electrode material, a separator, a negative electrode material, and a negative electrode current collector.

18. In paragraph 17, The above battery stack further includes an opening, The first cover and the second cover extend to a portion within the opening and are joined to each other within the opening, A battery integrated circuit board characterized in that the openings of the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector are larger than the openings of the separator, so that a portion of the separator is exposed inside the openings of the positive electrode current collector, the positive electrode material, the negative electrode material, and the negative electrode current collector.

19. In paragraph 17, The positive electrode current collector extends to the first side based on the positive electrode material, the separator, and the negative electrode material, A battery-integrated circuit board, characterized in that the negative electrode collector extends to a second side opposite to the first side.

20. In paragraph 17, A battery-integrated circuit board characterized in that the battery stack further includes an insulating layer for insulation between the unit batteries and the first cover and the second cover.

21. An electronic device comprising a battery-integrated frame according to any one of claims 1 to 12 or a battery-integrated circuit board according to any one of claims 13 to 20.

Images