Battery cell

Abstract

According to exemplary embodiments, a battery cell is provided. The battery cell comprises: first and second electrode assemblies including a first electrode tab and a second electrode tab; and a first terminal assembly coupled to each of the first and second electrode assemblies. The first terminal assembly includes: a first bus bar coupled to the first electrode tab of each of the first and second electrode assemblies; a first terminal coupled to the first bus bar; and a first housing including a hole penetrated by the terminal, and the first housing includes a first outer housing and a first inner housing embedded in the first outer housing.

Description

battery cell

[0001] The present invention relates to a battery cell. This application claims the benefit of Korean Application No. 10-2024-0078516, filed June 17, 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 in secondary batteries for mobility is improving energy density and safety. The energy density of a secondary battery is defined as the maximum electrical energy it can store divided by its mass. High energy density in secondary batteries is directly linked to driving efficiency and range in mobility, and therefore, various studies are being conducted to improve the energy density of secondary batteries.

[0004] The technical idea of ​​the present invention aims to solve a problem by providing a battery cell assembly having improved safety and reliability.

[0005] According to exemplary embodiments of the present invention for solving the above-described problem, a battery cell is provided. The battery cell includes first and second electrode assemblies including a first electrode tab and a second electrode tab; and a first terminal assembly coupled to each of the first and second electrode assemblies, wherein the first terminal assembly includes a first bus bar coupled to the first electrode tab of each of the first and second electrode assemblies; a first terminal coupled to the first bus bar; and a first housing including a hole penetrated by the terminal, and wherein the first housing includes a first outer housing and a first inner housing embedded in the first outer housing.

[0006] The first inner housing comprises metal.

[0007] The first inner housing comprises aluminum.

[0008] The first outer housing comprises an insulating material.

[0009] The first outer housing comprises a thermoplastic material.

[0010] The first outer housing comprises a polyphthalamide resin.

[0011] It further includes a cell case surrounding the first housing and the first and second electrode assemblies and heat-sealed to the first housing.

[0012] The above cell case is in contact with the first external housing.

[0013] The first inner housing includes a first surface and second to fifth surfaces surrounding the first surface, the second surface being opposite the third surface, and the fourth surface being opposite the fifth surface.

[0014] The first inner housing includes a first hole penetrated by the first terminal.

[0015] The above first hole is on the above first surface.

[0016] The first inner housing further includes second holes, and each of the second holes has a different width than the first hole.

[0017] The diameter of each of the second holes is smaller than the diameter of the first hole.

[0018] The above second holes are located on each of the first to fifth surfaces.

[0019] According to exemplary embodiments of the present invention, a battery cell housing may include an outer housing comprising a thermoplastic material and an inner housing embedded within the outer housing. This prevents short-circuiting of the inner housing, while also enabling thermal bonding to the pouch case without any additional treatment of the outer housing, thereby enhancing the mass production and mechanical robustness of the battery cell.

[0020] 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.

[0021] Figures 1 and 2 are perspective views of battery cells according to exemplary embodiments.

[0022] Figures 3 and 4 are exploded perspective views of battery cells according to exemplary embodiments.

[0023] Figure 5 is a cross-sectional view taken along the cutting line 1I-1I' of Figure 1.

[0024] Figure 6 is a cross-sectional view taken along the cutting line 1II-1II' of Figure 1.

[0025] FIG. 7 is a perspective view illustrating a battery cell assembly according to exemplary embodiments.

[0026] Figure 8 is a perspective view of a battery pack according to one embodiment of the present invention.

[0027] Figure 9 is an exploded perspective view of the battery pack of Figure 8.

[0028] Fig. 10 is a perspective view for explaining the battery pack of Fig. 8.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033]

[0034] Figures 1 and 2 are perspective views of a battery cell (100) according to exemplary embodiments. More specifically, Figure 2 is a perspective view of the battery cell (100) viewed from a different direction from Figure 1.

[0035] Figures 3 and 4 are exploded perspective views of a battery cell (100) according to exemplary embodiments. More specifically, Figure 4 is an exploded perspective view of a battery cell (100) viewed from a different direction from Figure 3.

[0036] Figure 5 is a cross-sectional view taken along the cutting line 1I-1I' of Figure 1.

[0037] Figure 6 is a cross-sectional view taken along the cutting line 1II-1II' of Figure 1.

[0038] Referring to FIGS. 1 to 6, a battery cell (100) may include electrode assemblies (110), a separator (115), a first terminal assembly (120), a second terminal assembly (130), and a cell case (140). The battery cell (100) may further include an electrolyte within the cell case (140).

[0039] Each of the electrode assemblies (110) may be either a jelly-roll type or a stack type. The jelly-roll type electrode assembly may include a winding structure of a positive electrode, a negative electrode, and a separator interposed therebetween. The stack type electrode assembly may include a plurality of sequentially stacked positive electrodes, a plurality of negative electrodes, and a plurality of separators interposed therebetween. The periphery of each of the electrode assemblies (110) may be surrounded by a separator, and thus, a short circuit between the electrode assemblies (110) due to the integrated contact of the electrode assemblies (110) may be prevented.

[0040] The thickness of the positive electrode current collector may range from about 3 μm to about 500 μm. The positive electrode current collector may not cause chemical changes in the secondary battery to be ultimately manufactured and may have high conductivity. The positive electrode current collector may include, for example, stainless steel, aluminum, nickel, titanium, calcined carbon, and aluminum. The positive electrode current collector may also include stainless steel surface-treated with carbon, nickel, titanium, silver, or the like. The surface of the positive electrode current collector may include a micro-roughened structure to increase the adhesion of the active material. The positive electrode current collector may have a shape such as a film, a sheet, a foil, a net, a porous material, a foam, or a non-woven fabric.

[0041] The thickness of the negative electrode current collector may be in the range of about 3 μm to about 500 μm. The negative electrode current collector may not cause chemical changes in the secondary battery ultimately manufactured and may have high conductivity. The negative electrode current collector may include copper, stainless steel, aluminum, nickel, titanium, sintered carbon, and an aluminum-cadmium alloy. The negative electrode current collector may also include stainless steel surface-treated with carbon, nickel, titanium, silver, etc. The surface of the negative electrode current collector may include a micro-roughened structure to increase the adhesion of the active material. The negative electrode current collector may have a shape such as a film, a sheet, a foil, a net, a porous material, a foam, or a non-woven fabric.

[0042] A cathode active material is a material capable of causing an electrochemical reaction. The cathode active material may be a lithium transition metal oxide. Examples of the cathode active material include layered compounds such as lithium cobalt oxide (LiCoO2) and lithium nickel oxide (LiNiO2) substituted with one or more transition metals; lithium manganese oxide substituted with one or more transition metals; chemical formula LiNi 1-y M yLithium nickel oxide expressed as O2 (wherein, M is any one of Co, Mn, Al, Cu, Fe, Mg, B, Cr, Zn, and Ga, and 0.01≤y≤0.7); Li 1+z Ni 1 / 3 Co 1 / 3 Mn 1 / 3 O2, Li 1+zN i 0.4 Mn 0.4 Co 0.2 Li like O2 1+z Ni b Mn c Co 1-(b+c+d) M d O (2-e) A e (wherein, -0.5≤z≤0.5, 0.1≤b≤0.8, 0.1≤c≤0.8, 0≤d≤0.2, 0≤e≤0.2, b+c+d<1, M is any one of Al, Mg, Cr, Ti, Si, and Y, and A is any one of F, P, and Cl) Lithium nickel cobalt manganese composite oxide; chemical formula Li 1+x M 1-y M' y PO 4-z X z (wherein, M is a transition metal, more specifically, one of Fe, Mn, Co, and Ni, M' is one of Al, Mg, and Ti, X is one of F, S, and N, -0.5≤x≤+0.5, 0≤y≤0.5, and 0≤z≤0.1) and may include an olivine-based lithium metal phosphate.

[0043] The negative active material may include carbon, such as non-graphitizable carbon, graphitic carbon, etc. The negative active material may include, for example, Li x Fe2O3(0≤x≤1), LixWO2(0≤x≤1), Sn x Me 1-x Me' y O z(wherein Me is any one of Mn, Fe, Pb and Ge, and Me' is any one of Al, B, P, Si, elements of group 1, 2 and 3 of the periodic table and halogens; 0 <x≤1 이고; 1≤y≤3 이며; 1≤z≤8) 등의 금속 복합 산화물을 포함할 수 있다. 음극 활물질은, 예컨대, 리튬 금속; 리튬 합금; 규소계 합금; 및 주석계 합금을 포함할 수 있다. 음극 활물질은, 예컨대, SnO, SnO2, PbO, PbO2, Pb2O3, Pb3O4, Sb2O3, Sb2O4, Sb2O5, GeO, GeO2, Bi2O3, Bi2O4, 및 Bi2O5등의 금속 산화물을 포함할 수 있다. 음극 활물질은, 예컨대, 폴리아세틸렌 등의 도전성 고분자; Li-Co-Ni 계 재료 등을 포함할 수 있다.

[0044] Each of the electrode assemblies (110) may include a plurality of first electrode tabs (110T1) and a plurality of second electrode tabs (110T2). The plurality of first electrode tabs (110T1) and the plurality of second electrode tabs (110T2) may have opposite polarities. For example, when each of the plurality of first electrode tabs (110T1) is a positive electrode tab, each of the plurality of second electrode tabs (110T2) may be a negative electrode tab.

[0045] The electrode assemblies (110) may be surrounded by a separator (115). The electrode assemblies (110) may be fixed to each other by the separator (115). The separator (115) may include, but is not limited to, a solid resin separator (SRS).

[0046] A first terminal assembly (120) can be coupled with electrode assemblies (110). The first terminal assembly (120) can include a first insulating frame (121), a first bus bar (123), a first housing (125), first terminals (127), first bus bar blocks (128), and first gaskets (129).

[0047] The first insulating frame (121) may be adjacent to the first electrode tabs (110T1). The distance between the first insulating frame (121) and the first electrode tabs (110T1) may be different from the distance between the first insulating frame (121) and the second electrode tabs (110T2). The distance between the first insulating frame (121) and the first electrode tabs (110T1) may be smaller than the distance between the first insulating frame (121) and the second electrode tabs (110T2).

[0048] The first insulating frame (121) can be coupled to the first housing (125). The first insulating frame (121) can be fixed to the first housing (125) in a force-fit manner. The first insulating frame (121) can protect a plurality of first electrode tabs (110T1). The first insulating frame (121) can include an insulating material such as polypropylene. When wrapping other elements of the battery cell (100) with the cell case (140), the first insulating frame (121) can prevent deformation and damage to the first electrode tabs (110T1) by filling the space around the first electrode tabs (110T1).

[0049] A plurality of first electrode tabs (110T1) can be coupled to a first bus bar (123). The plurality of first electrode tabs (110T1) can be welded to the first bus bar (123). The plurality of first electrode tabs (110T1) can be coupled to the first bus bar (123) by either laser welding or ultrasonic welding. The first bus bar (123) can include a conductive material. The first bus bar (123) can include, for example, a metal such as aluminum.

[0050] The first bus bar (123) may include a plurality of metal layers. Accordingly, the first bus bar (123) may be flexible and may include a curved shape. The first bus bar (123) may include holes (123H), and the holes (123H) may be penetrated by the first terminals (127).

[0051] The first housing (125) may include a first inner housing (125I) and a first outer housing (125O). The first inner housing (125I) may include a material having high rigidity. The first inner housing (125I) may include a metal such as aluminum, for example. The first outer housing (125O) may include an insulating material. The first outer housing (125O) may include, for example, a polyphthalamide resin and a thermoplastic material. The first outer housing (125O) may also include any one of polyamide, polyphenylene sulfide polyamide, polyetheretherketone, polycarbonate, polyoxymethylene, polysulfone, liquid crystal polymer, polybutylene terephthalate, and polyetherimide.

[0052] The first housing (125) can be provided by insert injection molding of the first inner housing (125I). Accordingly, in FIG. 3, the separation of the first inner housing (125I) and the first outer housing (125O) is illustrated, but after being provided by insert injection, it is difficult to separate the first inner housing (125I) and the first outer housing (125O) without at least partially removing the first outer housing (125O).

[0053] The first inner housing (125I) may have a roughly hexahedral shape, but may include only five faces, and thus may include an open space. A portion of the first insulating frame (121) may be inserted into the open space of the first inner housing (125I).

[0054] The first inner housing (125I) may include a first side (125IF1), a second side (125IF2), a third side (125IF3), a fourth side (125IF4), and a fifth side (125IF5). The first side (125IF1) may be surrounded by the second side (125IF2), the third side (125IF3), the fourth side (125IF4), and the fifth side (125IF5). The second side (125IF2) and the third side (125IF3) may be opposite to each other, and the fourth side (125IF4) and the fifth side (125IF5) may be opposite to each other. The length of each of the edges of the first face (125IF1) connected to the second face (125IF2) and the third face (125IF3) may be longer than the length of each of the edges of the first face (125IF1) connected to the fourth face (125IF4) and the fifth face (125IF5), but is not limited thereto.

[0055] The first side (125IF1) may face the first terminals (127). The first side (125IF1) may include first holes (125IH1) penetrated by the first terminals (127). The first side (125IF1) may further include second holes (125IH2). In the first side (125IF1), the first holes (125IH1) and the second holes (125IH2) may alternate. The second side (125IF2) and the third side (125IF3) may include a plurality of second holes (125IH2). The fourth side (125IF4) and the fifth side (125IF5) are illustrated as including one second hole (125IH2), but may also include two or more second holes (125IH2).

[0056] The second holes (125IH2) can be used for insert injection. The width (or diameter) of each of the second holes (125IH2) can be different from the width (or diameter) of each of the first holes (125IH1). The width (or diameter) of each of the second holes (125IH2) can be smaller than the width (or diameter) of each of the first holes (125IH1). Due to the second holes (125IH2), molten resin can be uniformly applied to the entire surface of the first inner housing (125I), and thus, the first inner housing (125I) can be embedded in the first outer housing (125O). According to exemplary embodiments, the first outer housing (125O) may include a portion interposed between the first inner housing (125I) and the first insulating frame (121), and a portion interposed between the first inner housing (125I) and the cell case (140).

[0057] The first outer housing (125O) may include holes (125OH), and the holes (125OH) may be penetrated by the first terminals (127). According to exemplary embodiments, the first outer housing (125O) prevents a short circuit between the first terminals (127) and the first inner housing (125I), so that provision of an additional component to prevent a short circuit between the first terminals (127) and the first inner housing (125I) is unnecessary.

[0058] Each of the first terminals (127) may include a cylindrical portion (127S) and a contact portion (127C). The contact portion (127C) of each of the first terminals (127) may protrude outside the first housing (125), thereby providing an electrical path between an external electrical element and the battery cell (100). The cylindrical portion (127S) of each of the first terminals (127) may pass through a corresponding one of the holes (123H), a corresponding one of the first holes (125IH1), and a corresponding one of the holes (125OH).

[0059] Each of the first terminals (127) may be configured to be electrically connected to the electrode assemblies (110). According to exemplary embodiments, each of the first terminals (127) may be, but is not limited to, a positive terminal of a battery cell (100). Each of the first terminals (127) may also be a negative terminal of a battery cell (100).

[0060] Each of the first terminals (127) may be spaced apart from the first bus bar (123) with a corresponding one of the first gaskets (129) therebetween. A corresponding one of the first bus bar blocks (128) may be coupled to the cylindrical portion (127S) of each of the first terminals (127). Each of the first bus bar blocks (128) may be in contact with a corresponding one of the first terminals (127) and the first bus bar (123), thereby providing an electrical connection between the first bus bar (123) and the first terminals (127). According to other exemplary embodiments, each of the first terminals (127) may also be in direct contact with the first bus bar (123).

[0061] The first bus bar (123) may include a portion interposed between the first bus bar blocks (128) and the first housing (125). The width of each of the first bus bar blocks (128) may be greater than the width (or diameter) of each of the holes (123H) of the first bus bar (123), thereby preventing separation of the first bus bar (123) and the first terminals (127). The first terminals (127) may be riveted, thereby fixing the first bus bar (123), the first bus bar blocks (128), and the first terminals (127).

[0062] Each of the first bus bar blocks (128) may have a plate shape including a hole (128H). Each of the first bus bar blocks (128) may have a square shape. The width (or diameter) of the hole (128H) of each of the first bus bar blocks (128) may be different from the width (or diameter) of each of the holes (123H) of the first bus bar (123). The width (or diameter) of the hole (128H) of each of the first bus bar blocks (128) may be smaller than the width (or diameter) of each of the holes (123H) of the first bus bar (123).

[0063] Within each of the holes (123H) of the first bus bar (123), there may be a portion of a terminal (127) and a portion of a corresponding one of the first gaskets (129). The inner peripheries of the first bus bar (123) defining the holes (123H) may surround one of the first terminals (127) and one of the first gaskets (129).

[0064] Within each of the holes (123H) of the first bus bar (123), there may be a cylindrical portion (127S) of a corresponding one of the first terminals (127) and a portion of a corresponding one of the first gaskets (129). The inner peripheries of the first bus bar (123) defining the holes (123H) may surround the cylindrical portion (127S) of the corresponding one of the first terminals (127) and the portion of the corresponding one of the first gaskets (129).

[0065] Within each hole (128H) of the first bus bar blocks (128), there may be a cylindrical portion (127S) of a corresponding one of the first terminals (127). The inner circumference of each of the first bus bar blocks (128) defining the hole (128H) of each of the first bus bar blocks (128) may surround the cylindrical portion (127S) of the corresponding one of the first terminals (127).

[0066] There may be first gaskets (129) between the first terminals (127) and the first housing (125). The first gaskets (129) may provide insulation and liquid-tightness to the first terminals (127). The first gaskets (129) may include, but are not limited to, any one of rubber, polyethylene, polyvinyl chloride, silicone, Teflon, polyamide, and fiber-reinforced plastic.

[0067] A second terminal assembly (130) can be coupled with the electrode assemblies (110). The second terminal assembly (130) can be spaced apart from the first terminal assembly with the electrode assemblies (110) therebetween. The second terminal assembly (130) can include a second insulating frame (131), a second bus bar (133), a second housing (135), second terminals (137), second bus bar blocks (138), and second gaskets (139).

[0068] The second insulating frame (131) may be adjacent to the second electrode tabs (110T2). The distance between the second insulating frame (131) and the second electrode tabs (110T2) may be different from the distance between the second insulating frame (131) and the first electrode tabs (110T1). The distance between the second insulating frame (131) and the second electrode tabs (110T2) may be smaller than the distance between the second insulating frame (131) and the first electrode tabs (110T1).

[0069] The second insulating frame (131) can be coupled to the second housing (135). The second insulating frame (131) can be fixed to the second housing (135) in a force-fit manner. The second insulating frame (131) can protect a plurality of second electrode tabs (110T1). The second insulating frame (131) can include an insulating material such as polypropylene. The second insulating frame (131) can prevent deformation and damage of the second electrode tabs (110T2) by filling the space around the second electrode tabs (110T2) when wrapping other elements of the battery cell (100) with the cell case (140).

[0070] A plurality of second electrode tabs (110T2) may be coupled to a second bus bar (133). A plurality of second electrode tabs (110T1) may be welded to a second bus bar (133). The plurality of second electrode tabs (110T1) may be coupled to the second bus bar (133) by either laser welding or ultrasonic welding. The second bus bar (133) may include a conductive material. The second bus bar (133) may include, for example, a metal such as copper.

[0071] The second bus bar (133) may include a plurality of metal layers. Accordingly, the second bus bar (133) may be flexible and may include a curved shape. The second bus bar (133) may include holes (133H), and the holes (133H) may be penetrated by the second terminals (137).

[0072] The second housing (135) may include a second inner housing (135I) and a second outer housing (135O). The second inner housing (135I) may include a material having high rigidity. The second inner housing (135I) may include a metal such as aluminum, for example. The second outer housing (135O) may include an insulating material such as polyphthalamide resin, for example. The second outer housing (135O) may also include any one of polyamide, polyphenylene sulfide, polyetheretherketone, polycarbonate, polyoxymethylene, polysulfone, liquid crystal polymer, polybutylene terephthalate, and polyetherimide.

[0073] The second housing (135) can be provided by insert injection molding of the second inner housing (135I). Accordingly, although the separation of the second inner housing (135I) and the second outer housing (135O) is illustrated in FIG. 3, after being provided by insert injection molding, it is difficult to separate the second inner housing (135I) and the second outer housing (135O) without at least partially removing the second outer housing (135O).

[0074] The second inner housing (135I) may have a roughly hexahedral shape, but may include only five faces, and thus may include an open space. A portion of the second insulating frame (131) may be inserted into the open space of the second inner housing (135I).

[0075] The second inner housing (135I) may include a first side (135IF1), a second side (135IF2), a third side (135IF3), a fourth side (135IF4), and a fifth side (135IF5). The first side (135IF1) may be surrounded by the second side (135IF2), the third side (135IF3), the fourth side (135IF4), and the fifth side (135IF5). The second side (135IF2) and the third side (135IF3) may be opposite to each other, and the fourth side (135IF4) and the fifth side (135IF5) may be opposite to each other. The length of each of the edges of the first face (135IF1) connected to the second face (135IF2) and the third face (135IF3) may be longer than the length of each of the edges of the first face (135IF1) connected to the fourth face (135IF4) and the fifth face (135IF5), but is not limited thereto.

[0076] The first side (135IF1) may face the second terminals (137). The first side (135IF1) may include first holes (131IH1) penetrated by the second terminals (137). The first side (135IF1) may further include second holes (131IH2). In the first side (135IF1), the first holes (131IH1) and the second holes (131IH2) may alternate. The second side (135IF2) and the third side (135IF3) may include a plurality of second holes (131IH2). The fourth side (135IF4) and the fifth side (135IF5) are illustrated as including one second hole (131IH2), but may also include two or more second holes (131IH2).

[0077] The second holes (131IH2) can be used for insert injection. Due to the second holes (131IH2), molten resin can be uniformly applied to the entire surface of the second inner housing (135I), and thus, the second inner housing (135I) can be embedded in the second outer housing (135O). According to exemplary embodiments, the second outer housing (135O) can include a portion interposed between the second inner housing (135I) and the second insulating frame (131), and a portion interposed between the second inner housing (135I) and the cell case (140).

[0078] The second outer housing (135O) may include holes (135OH), and the holes (135OH) may be penetrated by second terminals (137). Each of the second terminals (137) may include a cylindrical portion (137S) and a contact portion (137C). The contact portion (137C) of each of the second terminals (137) may protrude outside the second housing (135), thereby providing an electrical path between an external electrical element and the battery cell (100). The cylindrical portion (137S) of each of the second terminals (137) may penetrate a corresponding one of the holes (133H), a corresponding one of the second holes (135IH2), and a corresponding one of the holes (135OH).

[0079] Each of the second terminals (137) may be configured to be electrically connected to the electrode assemblies (110). According to exemplary embodiments, each of the second terminals (137) may be, but is not limited to, a negative terminal of a battery cell (100). Each of the second terminals (137) may also be a positive terminal of a battery cell (100).

[0080] Each of the second terminals (137) may be spaced apart from the second bus bar (133) with a corresponding one of the second gaskets (139) therebetween. Each of the second bus bar blocks (138) may be in contact with a corresponding one of the second terminals (137) and the second bus bar (133), thereby providing an electrical connection between the second bus bar (133) and the second terminals (137). According to other exemplary embodiments, each of the second terminals (137) may be in direct contact with the second bus bar (133).

[0081] The second bus bar (133) may include a portion interposed between the second bus bar blocks (138) and the housing (135). The width (or diameter) of each of the second bus bar blocks (138) may be larger than the width (or diameter) of each of the holes (133H) of the second bus bar (133), thereby preventing separation of the second bus bar (133) and the second terminals (137). The second terminals (137) may be riveted, thereby fixing the second bus bar (133), the second bus bar blocks (138), and the second terminals (137).

[0082] Each of the second bus bar blocks (138) may have a plate shape including a hole (138H). Each of the second bus bar blocks (138) may have a square shape. The width (or diameter) of the hole (138H) of each of the second bus bar blocks (138) may be different from the width (or diameter) of each of the holes (133H) of the second bus bar (133). The width (or diameter) of the hole (138H) of each of the second bus bar blocks (138) may be smaller than the width (or diameter) of each of the holes (133H) of the second bus bar (133).

[0083] Within each of the holes (133H) of the second bus bar (133), there may be a cylindrical portion (137S) of a corresponding one of the second terminals (137) and a portion of a corresponding one of the second gaskets (139). The inner peripheries of the second bus bar (133) defining the holes (133H) may surround the cylindrical portion (137S) of a corresponding one of the second terminals (137) and a corresponding one of the second gaskets (139).

[0084] Within each hole (138H) of the second bus bar blocks (138), there may be a cylindrical portion (137S) of a corresponding one of the second terminals (137). The inner circumference of each of the second bus bar blocks (138) defining the hole (138H) of each of the second bus bar blocks (138) may surround the cylindrical portion (137S) of the corresponding one of the second terminals (137).

[0085] Second gaskets (139) may be provided between the second terminals (137) and the second housing (135). The second gaskets (139) may provide insulation and liquid-tightness to the second terminals (137). The second gaskets (139) may include, but are not limited to, any one of rubber, polyethylene, polyvinyl chloride, silicone, Teflon, polyamide, and fiber-reinforced plastic.

[0086] The cell case (140) may be a pouch case including an aluminum laminate sheet. The cell case (140) may include an inner resin layer, a metal layer, and an outer resin layer. The inner resin layer may have heat-adhesive properties, thereby enabling sealing of the cell case (140). The inner resin layer may include, for example, a polyolefin-based material. 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.

[0087] The cell case (140) may enclose the electrode assemblies (110) and the first outer housing (125O) and the second outer housing (135O). According to exemplary embodiments, the first outer housing (125O) and the second outer housing (135O) include PPA resin or the like, so that the first outer housing (125O) and the second outer housing (135O) and the cell case (140) may be directly thermally bonded. That is, additional processes such as additional application of PPA and / or surface treatment may be omitted for thermal bonding of the first and second housings (125, 135) and the cell case (140).

[0088] The cell case (140) can be in contact with each of the first outer housing (125O) of the first housing (125) and the second outer housing (135O) of the second housing (135). Furthermore, since the first inner housing (125I) is embedded in the first outer housing (125O) and the second inner housing (135I) is embedded in the second outer housing (135O), the strength and reliability of the bonding between the housings (125, 135) and the cell case (140) can be improved.

[0089]

[0090] (Example 2)

[0091] FIG. 7 is a perspective view showing a battery cell assembly (10) according to exemplary embodiments.

[0092] Referring to FIGS. 1, 3, and 7, a battery cell assembly (10) may include a plurality of battery cells (100) and a plurality of pads (200).

[0093] A plurality of battery cells (100) may be arranged in the X direction. The first and second terminals (127, 137) of the plurality of battery cells (100) may be spaced apart from each other in the Y direction. The Z direction may be spaced apart from the X direction and the Y direction.

[0094] According to exemplary embodiments, the plurality of pads (200) may alternate with the plurality of battery cells (100) in the X direction. There may be a corresponding one of the plurality of battery cells (100) between two adjacent ones of the plurality of pads (200), and there may be a corresponding one of the plurality of pads (200) between two adjacent ones of the plurality of battery cells (100).

[0095] The plurality of pads (200) may include an elastic material. The plurality of pads (200) may include, for example, polyurethane. The plurality of pads (200) may absorb swelling of the plurality of battery cells (100). The plurality of pads (200) may also be thermal separators.

[0096]

[0097] (Example 3)

[0098] Figure 8 is a perspective view of a battery pack (1) according to one embodiment of the present invention.

[0099] Fig. 9 is an exploded perspective view of the battery pack (1) of Fig. 8.

[0100] FIG. 10 is a perspective view of the battery pack (1) of FIG. 8 with the pack cover (600) omitted to show the arrangement between elements of the battery pack (1).

[0101] Referring to FIGS. 8 to 10, a battery pack (1) according to one embodiment of the present invention may include a plurality of battery cell assemblies (10), a pack housing (300), cooling ports (410a, 410b), an electric component assembly (500), first to third inter-bus bars (510, 520, 530), and a pack cover (600).

[0102] The battery cell assemblies (10) may be loaded directly into the pack housing (300) without being housed within another frame. That is, the battery pack (1) may be of a modular type, and each of the battery cell assemblies (10) may not include a module frame, but is not limited thereto. A person skilled in the art will readily arrive at an embodiment in which each of the battery cell assemblies (10) includes a module frame based on the description herein.

[0103] The electric component assembly (500) may include a relay device, a current sensor, a fuse, a BMS (Battery Management System), and an MSD (Manual Service Disconnector). The relay device may be a switching device that selectively opens and closes a charging and discharging path through which current flows. The relay device may block the flow of charging and discharging current when an abnormality occurs in the battery pack (1). The BMS may be configured to control the overall charging and discharging operations of the battery assemblies (10). The MSD is a system for selectively cutting off the power of a high-voltage battery by a physical method. The MSD may be configured to disconnect the service plug to cut off the power as needed.

[0104] The pack housing (300) can provide a space for storing battery assemblies (10) and electrical component assemblies (500). The pack housing (300) can include a material (e.g., metal) having high rigidity in the battery cell assemblies (10) and electrical component assemblies (500), thereby protecting the battery assemblies (10) and electrical component assemblies (500) from external impact.

[0105] The pack housing (300) according to the present embodiment may include a flat base plate (310) and side walls (320, 330, 340, 350) that are approximately perpendicular to the base plate (310). Some of the side walls (330, 340) may include mounting wings (343, 353). The mounting wings (343, 353) may be used to load the battery pack (1) into an application (e.g., a vehicle). The brackets (332) may be used to secure the battery pack (1) to the application (e.g., a vehicle).

[0106] Two directions substantially parallel to the upper surface of the base plate (310) are defined as the X direction and the Y direction. Here, the X direction may be the direction in which the battery cells (100) are arranged. The Y direction may be substantially perpendicular to the X direction. A direction substantially perpendicular to each of the X direction and the Y direction is defined as the Z direction.

[0107] The pack housing (300) may further include a center beam (370) and cross beams (360) that define a space in which battery cell assemblies (10) are loaded. The center beam (370) and cross beams (360) may be on a base plate (310). The center beam (370) and cross beams (360) may be fixed to the base plate (310) by a method such as bolting and / or welding.

[0108] The center beam (370) can extend in the X direction. The center beam (370) can isolate the battery cell assemblies (10) in the Y direction. The center beam (370) can be interposed between the battery cell assemblies (10) in the Y direction. The cross beams (360) can extend in the Y direction. The cross beams (360) can be interposed between the battery cell assemblies (10) in the X direction. The cross beams (360) can isolate the battery cell assemblies (10) in the X direction.

[0109] The base plate (310), side walls (320, 330, 340, 350), cross beams (360), and center beam (370) can be provided by an extrusion process. Accordingly, the base plate (310), side walls (320, 330, 340, 350), cross beams (360), and center beam (370) can have a constant cross-section in the longitudinal direction, excluding changes due to mechanical tooling.

[0110] Cooling ports (410a, 410b) may be coupled to the base plate (310). The base plate (310) may include a plurality of cooling channels, and the cooling ports (410a, 410b) may be configured to introduce or discharge a cooling material into or from the plurality of cooling channels.

[0111] Each of the first inter-bus bars (510) can overlap with corresponding ones of the cross beams (360) and the center beam (370) in the Z direction. Each of the first inter-bus bars (510) can overlap with corresponding four of the plurality of battery cell assemblies (10) in the Z direction. The first inter-bus bars (510) can connect in series the battery cell assemblies (10) arranged in the X direction. The third inter-bus bar (530) can connect in series the battery cell assemblies (10) spaced apart in the Y direction.

[0112] The second inter-bus bar (520) may be output terminals for outputting the resulting voltage of a plurality of battery cell assemblies (10) connected in series by the first and third inter-bus bars (510, 530). The second inter-bus bar (520) may be connected to wiring connected to an external load and charging system directly or through an electric component assembly (500).

[0113]

[0114] The present invention has been described in more detail through the 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. First and second electrode assemblies including a first electrode tab and a second electrode tab; and A first terminal assembly coupled to each of the first and second electrode assemblies, The first terminal assembly comprises: a first bus bar coupled to the first electrode tab of each of the first and second electrode assemblies; a first terminal coupled to the first bus bar; and a first housing including a hole penetrated by the terminal; and A battery cell characterized in that the first housing comprises a first outer housing and a first inner housing embedded in the first outer housing.

2. In paragraph 1, A battery cell characterized in that the first inner housing comprises metal.

3. In paragraph 1, A battery cell characterized in that the first inner housing comprises aluminum.

4. In paragraph 1, A battery cell characterized in that the first outer housing comprises an insulating material.

5. In paragraph 1, A battery cell characterized in that the first outer housing comprises a thermoplastic material.

6. In paragraph 1, A battery cell characterized in that the first outer housing comprises a polyphthalamide resin.

7. In paragraph 1, A battery cell further comprising a cell case surrounding the first housing and the first and second electrode assemblies, and heat-sealed to the first housing.

8. In paragraph 7, A battery cell characterized in that the cell case is in contact with the first external housing.

9. In paragraph 1, The first inner housing includes a first surface and second to fifth surfaces surrounding the first surface, The second side is opposite to the third side, and A battery cell characterized in that the fourth side is opposite to the fifth side.

10. In paragraph 9, A battery cell, characterized in that the first inner housing includes a first hole penetrated by the first terminal.

11. In paragraph 10, A battery cell characterized in that the first hole is located on the first surface.

12. In paragraph 10, The first inner housing further includes second holes, and A battery cell characterized in that the width of each of the second holes is different from the width of the first hole.

13. In paragraph 12, A battery cell characterized in that the diameter of each of the second holes is smaller than the diameter of the first hole.

14. In paragraph 12, A battery cell characterized in that the second holes are located on each of the first to fifth sides.

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