Battery assembly and vehicle comprising same

Abstract

A battery assembly, according to the present invention, comprises: a plurality of batteries; a busbar electrically connected to electrode leads of the plurality of batteries; and a busbar frame coupled to the busbar so as to support the busbar, and provided with a busbar socket into which a portion of the busbar is inserted. The busbar comprises: a body portion to which the electrode leads are coupled so as to overlap each other; and a plug portion which is integrated with the body portion and extends from the body portion toward the busbar frame, and is inserted into the busbar socket so as to enable the body portion to be fixed to the busbar frame.

Description

Battery assembly and vehicle including same

[0001] This application claims priority from Korean Patent Application No. 10-2024-0108389, filed August 13, 2024, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a battery assembly and a vehicle including the same, and more particularly, to a battery assembly having a plurality of rechargeable batteries, and a battery pack and a vehicle including the battery assembly.

[0003] Typically, batteries capable of repeated charge and discharge, such as lithium ion batteries, lithium polymer batteries, nickel cadmium batteries, nickel metal hydride batteries, and nickel zinc batteries, can provide an output voltage of approximately 2.5 V to 4.2 V.

[0004] Recently, as these batteries are applied to devices that require high output voltage / current and large charging capacity, such as electric vehicles or ESS (Energy Storage Systems), battery assemblies such as battery modules or battery packs, which are composed of multiple batteries connected in series and / or parallel, are widely used.

[0005] However, existing technology has a problem in that the electrode leads of the batteries are connected to different parts of a bus bar having a wide plate shape in order to connect multiple batteries outputting high current in parallel or to connect the batteries connected in parallel in series with other batteries connected in parallel, so that the current path within the bus bar differs for each battery, resulting in a deviation in the current value output for each battery, and as a result, causing a difference in performance or an imbalance in charging capacity between the batteries.

[0006] In addition, since the existing technology connects the busbar and the busbar frame that supports the busbar through a separate fastening member and welds the electrode leads of the batteries to different parts of the busbar, it requires a lot of time and cost to assemble the battery assembly, and there is a problem that foreign substances such as spatter generated during the welding process may cause malfunction of the battery assembly, electrical short circuit, fire, etc.

[0007] The technical problem to be solved by the present invention is to provide a battery assembly that is easy to assemble and has a short assembly time, while reducing the deviation in the current value output by each battery and structurally preventing the difference in performance or imbalance in charging capacity between batteries, and a vehicle including such a battery assembly.

[0008] A battery assembly according to one aspect of the present invention comprises: a plurality of batteries; a bus bar electrically connected to electrode leads of the plurality of batteries; and a bus bar socket into which a portion of the bus bar is inserted, the bus bar frame being coupled to the bus bar and supporting the bus bar, wherein the bus bar includes a body portion into which the electrode leads are coupled while overlapping each other; and a plug portion integrally formed with the body portion and extending from the body portion toward the bus bar frame, the plug portion being inserted into the bus bar socket to fix the body portion to the bus bar frame.

[0009] In one embodiment, the body portion may have a band shape or a strap shape.

[0010] In one embodiment, the busbar socket may include a first socket and a second socket that are positioned spaced apart from each other with the busbar therebetween, and the plug portion may include a first plug and a second plug that are inserted into the first socket and the second socket, respectively.

[0011] In one embodiment, the plug portion has a through hole, and the busbar frame further has a coupling protrusion protruding from an inner surface of the busbar socket, and the coupling protrusion can be configured to be inserted into the through hole of the plug portion when the plug portion is inserted into the busbar socket.

[0012] In one embodiment, the battery assembly may further include a sensing circuit for sensing voltages of the plurality of batteries; and a connecting pin for electrically connecting the bus bar and the sensing circuit.

[0013] In one embodiment, the connection pin may include a first connection portion fixed to an inner surface of the busbar socket so as to come into contact with the plug portion inserted into the busbar socket; an extension portion having one end connected to the first connection portion and the other end extending from the inside of the busbar socket to the outside of the busbar socket; and a second connection portion extending from the other end of the extension portion and electrically connected to the sensing circuit.

[0014] In one embodiment, the connecting pin may be manufactured from a single metal plate.

[0015] In one embodiment, the busbar frame and the connecting pin can be formed integrally with each other by insert molding.

[0016] In one embodiment, the electrode leads of the plurality of batteries are joined to the body portion of the busbar by welding, and the busbar frame may further include a pocket provided in a portion of the busbar frame adjacent to the body portion and configured to capture foreign substances generated during the welding process.

[0017] In one embodiment, the battery assembly may further include a refractory cover that covers the inner surface of the pocket and is made of a material having a relatively higher melting point than the material forming the busbar frame.

[0018] In one embodiment, the plurality of batteries are arranged parallel to each other, and the electrode leads of a battery arranged relatively farther away from the bus bar among the plurality of batteries may be configured to be longer than the electrode leads of other batteries arranged relatively closer.

[0019] A vehicle according to another aspect of the present invention includes the battery assembly described above.

[0020] According to the present invention, electrode leads of a plurality of batteries included in a battery assembly are overlapped and connected to the same part of a bus bar, thereby allowing currents output from each of the plurality of batteries and passing through the bus bar to flow through the same path within the bus bar, thereby reducing deviations in current values ​​output from each battery and structurally preventing performance differences or imbalances in charging capacity between batteries.

[0021] In particular, the body of the busbar is configured to be fixed to the busbar frame by inserting the plug portion of the busbar into a busbar socket provided in the busbar frame, thereby facilitating assembly of the battery assembly and shortening the assembly time.

[0022] In addition, in one embodiment, when the plug portion of the bus bar is inserted into the bus bar socket, the bus bar and the sensing circuit of the battery assembly are configured to be electrically connected without separate wiring work, thereby simplifying the electrical connection structure of the battery assembly, and as a result, further shortening the assembly time of the battery assembly.

[0023] In addition, in one embodiment, a pocket configured to capture foreign substances generated during the process of welding the electrode leads to the busbar by overlapping each other is provided in the busbar frame, thereby preventing malfunction, electrical short circuit, fire, etc. of the battery assembly caused by small foreign substances such as spatter.

[0024] Furthermore, those skilled in the art will readily understand from the following description that various embodiments of the present invention can solve various technical problems not mentioned above.

[0025] FIG. 1 is a perspective view showing a battery assembly according to one embodiment of the present invention.

[0026] Fig. 2 is a perspective view showing a bus bar of the battery assembly illustrated in Fig. 1.

[0027] FIG. 3 is a drawing showing a portion of the busbar frame shown in area A1 of FIG. 1.

[0028] Figure 4 is a drawing showing the state before the busbar is connected to the busbar frame.

[0029] Figure 5 is a drawing showing a state in which a busbar is connected to a busbar frame.

[0030] Figure 6 is a drawing showing the state before the electrode leads of the batteries are welded to the bus bar.

[0031] Figure 7 is a drawing showing the state in which the electrode leads of the batteries are welded to the bus bar.

[0032] Fig. 8 is a cross-sectional view taken along line S1-S1' of Fig. 7.

[0033] Figure 9 is a drawing showing a vehicle according to one embodiment of the present invention.

[0034] Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings to clarify solutions addressing the technical challenges of the present invention. However, if a description of a related known technology obscures the essence of the present invention, the description thereof may be omitted.

[0035] Additionally, the terms used in this specification are defined based on their functions within the present invention, and may vary depending on the intent or custom of the designer, manufacturer, etc. Therefore, the definitions of terms described below should be based on the contents throughout this specification.

[0036] In addition, even without separate explanation, it is made clear in advance that various embodiments related to different components of the present invention can be combined with each other in various cases, as long as they do not technically conflict.

[0037] FIG. 1 is a perspective view showing a battery assembly according to one embodiment of the present invention.

[0038] As illustrated in FIG. 1, a battery assembly (100) according to one embodiment of the present invention includes a plurality of batteries (110), a bus bar (120), and a bus bar frame (130).

[0039] The above-described plurality of batteries (110) are each secondary batteries capable of repeated charging and discharging, and can be stacked and fixed side by side in one direction (X-axis direction). In this case, the battery assembly (100) may further include a pair of end plates (102) that support the plurality of batteries (110) so that the stacked state of the plurality of batteries (110) is maintained.

[0040] Additionally, each battery (110) included in the battery assembly (100) may be implemented as a battery of various types. For example, each battery (110) may be implemented as a pouch-type battery or a square battery.

[0041] The above bus bar (120) is configured to be electrically connected to the electrode leads (112) of a plurality of batteries (110). This bus bar (120) can be manufactured from a durable and conductive metal material.

[0042] The above busbar frame (130) is configured to be coupled with a busbar (120) and support the busbar (120). The busbar frame (130) may be composed of a material having electrical insulation and fire resistance. For example, the busbar frame (130) may be manufactured from a material including one or two or more of polyimide, aromatic polyamide, polyphenylene sulfide, polyether ether ketone, fluoropolymer, and ceramic.

[0043] In one embodiment, the battery assembly (100) may further include a sensing circuit (140). In this case, the sensing circuit (140) may be configured to sense the voltage of the battery (110) connected to the bus bar (120). This sensing circuit (140) may be implemented as a flexible printed circuit board (FPCB).

[0044] Fig. 2 is a perspective view showing a bus bar (120) of the battery assembly illustrated in Fig. 1.

[0045] As shown in FIG. 2, the bus bar (120) may include a body portion (122) and a plug portion (124).

[0046] The above body part (122) has a first surface (F1) facing the busbar frame (130) and a second surface (F2) located opposite the first surface (F1), and is configured such that the electrode leads of the batteries overlap and are coupled to the second surface (F2). This body part (122) may have a band shape or a strap shape.

[0047] The plug portion (124) is integrally formed with the body portion (122) and extends from the body portion (122) toward the busbar frame (130) described above. The plug portion (124) is configured to be inserted into and coupled to a busbar socket provided in the busbar frame (130), thereby fixing the body portion (122) to the busbar frame (130). To this end, the plug portion (124) may include a first plug (124a) and a second plug (124b) that are spaced apart from each other and extend in parallel.

[0048] These bus bars (120) can be manufactured from a single metal plate.

[0049] As will be described again below, the plug portion (124) of the bus bar (120) may have a through hole (126). This through hole (126) may be used for the connection between the plug portion (124) and the bus bar frame (130).

[0050] FIG. 3 is a drawing showing a portion of the busbar frame (130) shown in area A1 of FIG. 1.

[0051] As shown in FIG. 3, the busbar frame (130) has a support (132) and a busbar socket (134).

[0052] The above support member (132) is configured to contact the bus bar (120) and support the bus bar (120). In particular, the support member (132) may be configured to contact the body part (122) of the above-described bus bar (120).

[0053] The above bus bar socket (134) is configured so that a part of the bus bar (120), i.e., the plug part (124) of the above-described bus bar (120), is inserted and connected.

[0054] In one embodiment, the busbar socket (134) may include a first socket (134a) and a second socket (134b) that are positioned spaced apart from each other with the busbar (120) therebetween. In this case, the first plug (124a in FIG. 2) of the plug portion (124) may be inserted into the first socket (134a), and the second plug (124b in FIG. 2) of the plug portion (124) may be inserted into the second socket (134b).

[0055] Meanwhile, as described with reference to FIG. 2, the plug portion (124) of the bus bar (120) may have a through hole (126). In this case, the bus bar frame (130) may have a coupling protrusion (136) protruding from the inner surface of the bus bar socket (134). This coupling protrusion (136) may be configured to be inserted into the through hole (126) of the plug portion (124) of the bus bar (120) when the plug portion (124) of the bus bar (120) is inserted into the bus bar socket (134). For example, the plug portion (124) of the bus bar (120) and the coupling protrusion (136) may be configured to be mutually coupled in a snap-fit ​​manner.

[0056] In addition, the busbar frame (130) may be provided with a plurality of slots (137) provided on both sides of the support portion (132) with the support portion (132) as the center. The electrode lead of the battery connected to the busbar (120) coupled to the busbar frame (130) may extend toward the busbar (120) through the slots (137) of the busbar frame (130).

[0057] In one embodiment, the battery assembly (100) may include a connecting pin (150). The connecting pin (150) may be configured to electrically connect the bus bar (120) coupled to the bus bar socket (134) to the sensing circuit (140) described with reference to FIG. 1. In this case, the connecting pin (150) may be electrically connected to the sensing circuit (140) via a conductive line (CL). For example, the conductive line (CL) may be implemented as a Flat Flexible Cable (FFC) or a conductive pattern.

[0058] In addition, in one embodiment, the busbar frame (130) may be provided with a pocket (138) provided in a portion of the busbar frame (130) adjacent to the body portion (122) of the busbar (120). This pocket (138) may be configured to capture foreign substances such as spatter generated during the process of laser welding the electrode leads of batteries to the body portion (122) of the busbar (120). To this end, the pocket (138) may have a capture space that is concavely formed in a direction away from the busbar (120) (Y-axis direction).

[0059] Additionally, in one embodiment, the battery assembly (100) may further include a refractory cover (160) covering the inner surface of the pocket (138). The refractory cover (160) may be manufactured from a material having a relatively higher melting point than the material forming the busbar frame (130). For example, the refractory cover (160) may be manufactured from a material including ceramic or a material including stainless steel.

[0060] Figure 4 is a drawing showing the state before the bus bar (120) is connected to the bus bar frame (130).

[0061] As illustrated in FIG. 4, the connecting pin (150) may include a first connecting portion (152), an extension portion (154), and a second connecting portion (156).

[0062] In this case, the first connecting portion (152) is fixed to the inner surface of the busbar socket (134) so ​​as to come into contact with the plug portion (124) of the busbar (120) inserted into the busbar socket (134).

[0063] The above extension (154) has one end connected to the first connection (152) and the other end extends from the inside of the busbar socket (134) to the outside of the busbar frame (130).

[0064] The second connection portion (156) extends from the other end of the extension portion (154) and is electrically connected to the sensing circuit (140).

[0065] In one embodiment, the connecting pin (150) may be manufactured from a single metal plate. Additionally, the busbar frame (130) and the connecting pin (150) may be formed integrally with each other by insert molding.

[0066] Figure 5 is a drawing showing a state in which a bus bar (120) is connected to a bus bar frame (130).

[0067] As shown in Fig. 5, when the plug portion (124) of the busbar (120) is inserted into the busbar socket (134) of the busbar frame (130), the coupling protrusion (136) of the busbar frame (130) can be inserted into the through hole (126) of the plug portion (124) and coupled.

[0068] In addition, when the plug portion (124) of the bus bar (120) is inserted into the bus bar socket (134) of the bus bar frame (130), the plug portion (124) comes into contact with the first connection portion (152) of the connection pin (150). As a result, without a separate wiring work, the bus bar (120) can be electrically connected to the sensing circuit (140) described above through the first connection portion (152), the extension portion (154), and the second connection portion (156) of the connection pin (150).

[0069] Figure 6 is a drawing showing the state before the electrode leads (112a, 112b, 112c) of the batteries (110a, 110b, 110c) are welded to the bus bar (120).

[0070] As illustrated in Fig. 6, batteries (110a, 110b, 110c) connected to a busbar (120) may be arranged in parallel with each other. In addition, electrode leads (112a, 112b, 112c) of the batteries (112a, 112b, 112c) may each extend to the front side of the busbar frame (130) to which the busbar (120) is coupled through slots (137) of the busbar frame (130).

[0071] The distance between the bus bar (120) and each electrode lead (112a, 112b, 112c) varies for each battery. Therefore, among the batteries (110a, 110b, 110c), the electrode lead (112c) of a battery (110c) that is positioned relatively farther away from the bus bar (120) may be configured to be longer than the electrode leads (112a, 112b) of other batteries (110a, 110b) that are positioned relatively closer.

[0072] Figure 7 is a drawing showing the state in which the electrode leads of the batteries are welded to the bus bar.

[0073] As shown in Fig. 7, the electrode leads (112) of the batteries that pass through the slots (137) of the busbar frame (130) can be bent toward the busbar (120) that is coupled to the support (132) of the busbar frame (130) and then overlapped with each other to be coupled to the same part of the busbar (120).

[0074] Accordingly, the above-described sensing circuit (140) is electrically connected to the corresponding batteries through the connection pin (150) and the bus bar (120), and can sense the voltage of the corresponding batteries.

[0075] Fig. 8 is a cross-sectional view taken along line S1-S1' of Fig. 7.

[0076] As illustrated in Fig. 8, the electrode leads (112) of the batteries (110a, 110b, 110c) electrically connected to the bus bar (120) can be simultaneously joined to the body (122) of the bus bar (120) by laser welding. During this laser welding process, foreign substances such as spatters may also be generated in the rear direction (Y-axis direction) of the bus bar (120) depending on the intensity of the laser used to weld the electrode leads (112a, 112b, 112c).

[0077] The pocket (138) of the busbar frame (130) described above is provided at a position adjacent to the body (122) of the busbar (120) and can capture foreign substances generated as described above.

[0078] In addition, the refractory cover (160) manufactured from a material having a relatively higher melting point than the material forming the busbar frame (130) covers the inner surface of the pocket (138), thereby preventing melting or damage to the busbar frame (130) caused by high-temperature foreign substances generated during laser welding.

[0079] In some embodiments, an elastic insulating pad (104) may be interposed between the mutually stacked batteries of the battery assembly (100). This insulating pad (104) may be made of a material including silicon.

[0080] Figure 9 is a drawing showing a vehicle according to one embodiment of the present invention.

[0081] As illustrated in FIG. 9, a vehicle (2) according to one embodiment of the present invention may include a battery assembly (100) according to various embodiments described above. Depending on the embodiment, the vehicle (2) may include two or more of the battery assemblies (100) described above.

[0082] In this case, the battery assembly (100) may further include a case (170) that accommodates the plurality of batteries (110) described above, a busbar frame (130) in which the busbar (120) is combined, and a sensing circuit (140).

[0083] In addition, the battery assembly (100) may further include a BMS (Battery Management System) (not shown) that controls the charging and discharging operations of the plurality of batteries (110) or monitors SOC (State Of Charge), SOH (State Of Health), etc. Such a BMS may be accommodated in the case (170).

[0084] Such a battery assembly (100) can provide electric energy required for various operations of the vehicle (2).

[0085] For reference, the battery assembly (100) according to the present invention can be applied to various electric devices or electric systems other than vehicles, and can also be applied to ESS (Energy Storage System).

[0086] As described above, according to the present invention, the electrode leads of a plurality of batteries included in a battery assembly are overlapped and connected to the same part of a bus bar, thereby allowing currents output from each of the plurality of batteries and passing through the bus bar to flow through the same path within the bus bar, thereby reducing the deviation in the current value output from each battery and structurally preventing performance differences or imbalances in charging capacities between batteries.

[0087] In particular, the body of the busbar is configured to be fixed to the busbar frame by inserting the plug portion of the busbar into a busbar socket provided in the busbar frame, thereby facilitating assembly of the battery assembly and shortening the assembly time.

[0088] In addition, in one embodiment, when the plug portion of the bus bar is inserted into the bus bar socket, the bus bar and the sensing circuit of the battery assembly are configured to be electrically connected without separate wiring work, thereby simplifying the electrical connection structure of the battery assembly, and as a result, further shortening the assembly time of the battery assembly.

[0089] In addition, in one embodiment, a pocket configured to capture foreign substances generated during the process of welding the electrode leads to the busbar by overlapping each other is provided in the busbar frame, thereby preventing malfunction, electrical short circuit, fire, etc. of the battery assembly caused by small foreign substances such as spatter.

[0090] Furthermore, it goes without saying that embodiments according to the present invention can solve various technical problems other than those mentioned in this specification, not only in the relevant technical field but also in related technical fields.

[0091] The present invention has been described with reference to specific embodiments. However, those skilled in the art will clearly understand that various modifications can be implemented within the technical scope of the present invention. Therefore, the embodiments disclosed above should be considered illustrative rather than limiting. In other words, the true scope of the present invention is set forth in the claims, and all differences within the scope equivalent thereto should be construed as being encompassed by the present invention.

[0092] [Explanation of symbols]

[0093] 100: Battery assembly

[0094] 110: Battery

[0095] 120: Busbar

[0096] 122: Body

[0097] 124: Plug section

[0098] 126: Through hole

[0099] 130: Busbar frame

[0100] 132: Support

[0101] 134: Busbar socket

[0102] 136: Combination protrusion

[0103] 138: Pocket

[0104] 140: Sensing circuit

[0105] 150: Connection pin

[0106] 160: Fireproof cover

Claims

1. Multiple batteries; A bus bar electrically connected to the electrode leads of the plurality of batteries; and A busbar socket into which a portion of the above busbar is inserted is provided, and a busbar frame is included that is coupled with the busbar and supports the busbar. The above bus bar, A body part in which the above electrode leads are joined to each other by overlapping each other; and A battery assembly comprising a plug portion that is integral with the body portion and extends from the body portion toward the busbar frame, and is configured to secure the body portion to the busbar frame by being inserted into the busbar socket.

2. In paragraph 1, A battery assembly characterized in that the above body part has a band shape or a strap shape.

3. In paragraph 1, The above busbar socket includes a first socket and a second socket which are positioned spaced apart from each other with the busbar therebetween, A battery assembly characterized in that the plug portion includes a first plug and a second plug that are inserted into the first socket and the second socket, respectively.

4. In paragraph 1, The above plug portion has a through hole, The above busbar frame further has a coupling projection protruding from the inner surface of the busbar socket, A battery assembly characterized in that the above coupling protrusion is configured to be inserted into the through hole of the plug portion when the plug portion is inserted into the bus bar socket.

5. In paragraph 1, A sensing circuit for sensing the voltage of the plurality of batteries; and A battery assembly further comprising a connecting pin electrically connecting the bus bar and the sensing circuit.

6. In paragraph 5, The above connection pins are, A first connecting portion fixed to the inner surface of the busbar socket so as to be in contact with the plug portion inserted into the busbar socket; An extension part having one end connected to the first connection part and the other end extending from the inside of the busbar socket to the outside of the busbar socket; and A battery assembly characterized by including a second connecting portion extending from the other end of the extension portion and electrically connected to the sensing circuit.

7. In paragraph 5, A battery assembly, characterized in that the above connecting pin is manufactured from a single metal plate.

8. In paragraph 5, A battery assembly characterized in that the busbar frame and the connecting pin are formed integrally with each other by insert molding.

9. In paragraph 1, The electrode leads of the plurality of batteries are joined to the body of the bus bar by welding, A battery assembly characterized in that the busbar frame further comprises a pocket provided on a portion of the busbar frame adjacent to the body portion and configured to capture foreign substances generated during the welding process.

10. In paragraph 9, A battery assembly characterized in that it further includes a fireproof cover that covers the inner surface of the pocket and is manufactured from a material having a relatively higher melting point than the material forming the busbar frame.

11. In paragraph 1, The above plurality of batteries are arranged parallel to each other, A battery assembly characterized in that the electrode leads of a battery positioned relatively farther away from the bus bar among the plurality of batteries are configured to be longer than the electrode leads of other batteries positioned relatively closer.

12. A vehicle comprising a battery assembly according to any one of claims 1 to 11.

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