Busbar frame assembly and battery assembly including same

Abstract

A busbar frame assembly according to an embodiment of the present invention includes: a busbar connected to a plurality of battery cells; a printed circuit board (PCB) connected to the busbar to sense voltages of the battery cells; a first reinforcing plate and a second reinforcing plate disposed in different regions of the printed circuit board; and a busbar frame in which the busbar is disposed.

Description

Busbar frame assembly and battery assembly including the same

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority based on Korean Patent Application No. 10-2024-0124387 filed September 12, 2024, and all contents disclosed in the document of said Korean patent application are incorporated herein as part of this specification.

[0003] The present invention relates to a busbar frame assembly and a battery assembly including the same, and more specifically, to a busbar frame assembly having a flattening structure of a printed circuit board (PCB) through the separation of a reinforcing plate and a battery assembly including the same.

[0004] In modern society, as the use of portable devices such as mobile phones, laptops, camcorders, and digital cameras has become commonplace, the development of technologies related to such mobile devices is becoming active. Furthermore, rechargeable secondary batteries are being utilized as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (P-HEVs) as a solution to address air pollution caused by conventional gasoline vehicles using fossil fuels; consequently, the need for the development of secondary batteries is increasing.

[0005] Currently commercialized rechargeable batteries include nickel-cadmium, nickel-hydrogen, nickel-zinc, and lithium-ion batteries. Among these, lithium-ion batteries are gaining attention for their advantages, such as the ability to charge and discharge freely with almost no memory effect compared to nickel-based batteries, a very low self-discharge rate, and high energy density.

[0006] These lithium secondary batteries primarily use lithium-based oxides and carbon materials as the positive and negative active materials, respectively. The lithium secondary battery comprises an electrode assembly in which a positive plate and a negative plate, each coated with the positive and negative active materials, are arranged with a separator in between, and a battery case that seals and houses the electrode assembly together with an electrolyte.

[0007] Generally, lithium secondary batteries can be classified according to the shape of the casing into can-type secondary batteries, in which the electrode assembly is embedded in a metal can, and pouch-type secondary batteries, in which the electrode assembly is embedded in a pouch of aluminum laminate sheet.

[0008] In the case of secondary batteries used in small devices, 2 to 3 battery cells are arranged, whereas in the case of secondary batteries used in medium to large devices such as automobiles, battery modules in which multiple battery cells are electrically connected are used. In such battery modules, capacity and output are improved by connecting multiple battery cells in series or parallel to form a stack of battery cells. In addition, one or more battery modules can be mounted together with various control and protection systems, such as a Battery Disconnect Unit (BDU), a Battery Management System (BMS), and a cooling system, to form a battery pack.

[0009] Meanwhile, a busbar connected to a battery module is provided inside the battery pack. Conventional busbars are rod-shaped metal members extending along the longitudinal direction, and through holes may be formed at both ends of the busbar for connection to the terminal busbars of the battery module. Such a busbar is a component responsible for HV (High Voltage) connection in the battery pack. HV connection refers to a connection that serves as a power source to supply electricity, and as a component that guides the electrical connection of the battery module, the busbar generally comprises a metal material with excellent electrical conductivity. For example, the busbar may include copper (Cu) material.

[0010] The problem that the present invention aims to solve is to resolve the issues of quality risk and increased manufacturing costs caused by the bending process of conventional printed circuit boards. Specifically, it provides a busbar frame assembly and a battery assembly including the same that can maintain the flatness of the printed circuit board through the separate placement of reinforcing plates, reduce manufacturing costs by eliminating unnecessary bending processes, and reduce quality problems such as cracks and tearing of the printed circuit board.

[0011] However, the problems that the embodiments of the present invention aim to solve are not limited to the problems described above and can be expanded in various ways within the scope of the technical ideas included in the present invention.

[0012] A busbar frame assembly according to one embodiment of the present invention comprises: a busbar connected to a plurality of battery cells; a printed circuit board (PCB) connected to the busbar for voltage sensing of the battery cells; a first reinforcing plate and a second reinforcing plate disposed in each of different regions of the printed circuit board; and a busbar frame on which the busbar is disposed.

[0013] The second reinforcing plate can be separated from the first reinforcing plate and positioned on a plane different from one side of the first reinforcing plate.

[0014] The second reinforcing plate may be located on the same plane as one side of the busbar.

[0015] The above printed circuit board can be in close contact with the first reinforcing plate and the second reinforcing plate.

[0016] Except for the area between the first reinforcing plate and the second reinforcing plate, the printed circuit board may not be bent.

[0017] The area of ​​the printed circuit board connected to the module connector can be in close contact with the first reinforcing plate.

[0018] The second reinforcing plate may be closer to the busbar than the first reinforcing plate.

[0019] The first reinforcing plate and the second reinforcing plate may be disposed on one side of the busbar frame.

[0020] The first reinforcing plate, the second reinforcing plate, and the printed circuit board can be fixed to the busbar frame by heat fusion bonding.

[0021] According to another embodiment of the present invention, a battery assembly comprising the busbar frame assembly is provided.

[0022] According to embodiments of the present invention, manufacturing costs can be reduced by eliminating the bending process applied to conventional printed circuit boards through the separate arrangement of reinforcing plates and the flattening structure of the printed circuit board. In addition, quality issues such as cracking and tearing of the printed circuit board can be reduced by ensuring the structural stability of the printed circuit board. Through this, the reliability of the battery assembly can be increased and the accuracy of battery cell voltage sensing can be maintained.

[0023] The effects of the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by those skilled in the art from the description in the claims.

[0024] FIG. 1 is a perspective view showing a busbar frame assembly according to one embodiment of the present invention.

[0025] Figure 2 is a plan view showing the busbar frame assembly of Figure 1.

[0026] Figure 3 is a plan view showing the busbar frame assembly of Figure 1 viewed from a different angle than that of Figure 2.

[0027] Figure 4 is a cross-sectional view showing a cross-section cut along the cutting line A-A' of Figure 2.

[0028] Figure 5 is a cross-sectional view showing a cross-section cut along the cutting line B-B' of Figure 2.

[0029] FIG. 6 is a perspective view showing a printed circuit board according to one embodiment of the present invention.

[0030] Figure 7 is a cross-sectional view showing a cross-section cut along the cutting line C-C' of Figure 2.

[0031] Hereinafter, various embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the present invention. The present invention may be embodied in various different forms and is not limited to the embodiments described herein.

[0032] To clearly explain the present invention, parts unrelated to the explanation have been omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0033] Furthermore, the size and thickness of each component shown in the drawings are depicted arbitrarily for convenience of explanation, and thus the present invention is not necessarily limited to what is illustrated. Thicknesses have been enlarged in the drawings to clearly represent various layers and regions. Additionally, for convenience of explanation, the thickness of some layers and regions has been exaggerated in the drawings.

[0034] Furthermore, when a part such as a layer, membrane, region, or plate is said to be "on" or "on" another part, this includes not only the case where it is "directly above" the other part, but also the case where there is another part in between. Conversely, when a part is said to be "directly above" another part, it means that there is no other part in between. Also, saying that a part is "on" or "on" a reference part means that it is located above or below the reference part, and does not necessarily mean that it is located "on" or "on" facing the opposite direction of gravity.

[0035] Furthermore, throughout the specification, when a part is described as "including" a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0036] Additionally, throughout the specification, "planar" means when the subject part is viewed from above, and "cross-sectional" means when the cross-section obtained by vertically cutting the subject part is viewed from the side.

[0037] FIG. 1 is a perspective view showing a busbar frame assembly according to an embodiment of the present invention. FIG. 2 is a plan view showing the busbar frame assembly of FIG. 1. FIG. 3 is a plan view showing the busbar frame assembly of FIG. 1 viewed from an angle different from that of FIG. 2.

[0038] Referring to FIGS. 1 to 3, a busbar frame assembly (100) according to one embodiment of the present invention comprises: a busbar (120) connected to a plurality of battery cells; a printed circuit board (130, Printed Circuit Board, PCB) connected to the busbar (120) for voltage sensing of the battery cells; a first reinforcing plate (140) and a second reinforcing plate (150) disposed in each of different regions of the printed circuit board (130); and a busbar frame (160) on which the busbar (120) is disposed.

[0039] The busbar (120) according to the present embodiment can be electrically connected to a battery cell. The busbar (120) is configured to guide electrical connections between battery cells within a battery assembly or to guide electrical connections of the battery assembly, and it is sufficient to include a metal material with excellent electrical conductivity, and is not limited to its shape or material. For example, the battery cell may include an electrode lead or an electrode terminal that is connected to an electrode assembly inside and has a portion exposed to the outside. The busbar (120) can be electrically connected to the battery cell by being connected to such an electrode lead or electrode terminal.

[0040] The printed circuit board (130) according to the present embodiment is configured to sense voltage data or thermal data of battery cells. For example, the printed circuit board (130) may be connected to the electrode leads or electrode terminals or busbar (120) of the battery cells. Accordingly, the printed circuit board (130) can sense voltage data of each battery cell and transmit it to an external Battery Management System (BMS). The BMS can control the operation of the battery assembly based on the voltage data of the battery cells included in the battery assembly.

[0041] A busbar (120) may be mounted on the busbar frame (160) according to the present embodiment. The busbar frame (160) may include an electrical insulating material to prevent the busbar (120) from coming into contact with other parts of the battery cell and causing a short circuit. The busbar frame (160) may function to fix the busbar (120) and stably maintain the connection with the printed circuit board (130).

[0042] According to the present embodiment, a first reinforcing plate (140) and a second reinforcing plate (150) for supporting a printed circuit board (130) may be placed in different areas of the printed circuit board (130). The first reinforcing plate (140) and the second reinforcing plate (150) may be designed so that mechanical deformation of the printed circuit board (130) is minimized during the process of the printed circuit board (130) being connected to the bus bar (120). Through this, mechanical stability of the printed circuit board (130) can be secured, and voltage sensing between battery cells can be performed accurately. That is, the connection between the bus bar (120) and the printed circuit board (130) is stably formed, so that accurate transmission of electrical signals can be made possible.

[0043] Figure 4 is a cross-sectional view showing a cross-section cut along the cutting line A-A' of Figure 2.

[0044] Referring to FIGS. 1 to 4, the second reinforcing plate (150) may be separated from the first reinforcing plate (140) and positioned on a plane different from one side of the first reinforcing plate (140). For example, in FIG. 4, the first reinforcing plate (140) and the second reinforcing plate (150) may each be positioned on virtual planes that are positioned differently along the Y-axis direction.

[0045] Specifically, the first reinforcing plate (140) is positioned on the upper part of the printed circuit board (130) to support the main circuit area of ​​the printed circuit board (130), and the second reinforcing plate (150) is positioned on the lower part or side of the printed circuit board (130) to support the connection area between the printed circuit board (130) and the bus bar (120). The second reinforcing plate (150) can function to distribute mechanical stress that may occur when the printed circuit board (130) is connected to the bus bar (120) and to maintain the flatness of the printed circuit board (130). This arrangement can contribute to ensuring the stability of the electrical connection by ensuring that the printed circuit board (130) is accurately fixed to the bus bar (120). The first reinforcing plate (140) and the second reinforcing plate (150) can be positioned at different heights and locations, thereby preventing deformation that may occur in specific areas of the printed circuit board (130). In addition, it can reduce electrical contact failures and increase the accuracy of battery cell voltage sensing.

[0046] Figure 5 is a cross-sectional view showing a cross-section cut along the cutting line B-B' of Figure 2.

[0047] Referring to FIGS. 1 to 3 and FIG. 5, the second reinforcing plate (150) may be located on the same plane as one side of the bus bar (120).

[0048] The second reinforcing plate (150) according to the present embodiment is adjusted to match the height of the bus bar (120), so that the printed circuit board (130) can be fixed flat without bending. Through this, when the printed circuit board (130) is attached to the bus bar (120), the contact surface between the printed circuit board (130) and the bus bar (120) can be maintained evenly. In addition, mechanical stress that may occur when the printed circuit board (130) is connected to the bus bar (120) can be minimized, and the electrical connection between the printed circuit board (130) and the bus bar (120) can be maintained stably.

[0049] FIG. 6 is a perspective view showing a printed circuit board (130) according to one embodiment of the present invention.

[0050] Referring to FIGS. 1 to 4 and FIGS. 6, the printed circuit board (130) can be in close contact with the first reinforcing plate (140) and the second reinforcing plate (150).

[0051] The printed circuit board (130) according to the present embodiment may be positioned to be in close contact with the first reinforcing plate (140) and the second reinforcing plate (150). This close contact structure can prevent the printed circuit board (130) from being deformed by external forces and, in particular, can prevent defects that may occur in electrical connection parts. The printed circuit board (130) is supported vertically by the first reinforcing plate (140) and the second reinforcing plate (150) and can be maintained in a state of close contact with the first reinforcing plate (140) and the second reinforcing plate (150). The closely contacted printed circuit board (130) can maintain structural stability despite external impact. An adhesive may be provided between the first reinforcing plate (140), the second reinforcing plate (150), and the printed circuit board (130), and the first reinforcing plate (140), the second reinforcing plate (150), and the printed circuit board (130) may be joined through a mechanical fixing device.

[0052] Referring again to FIGS. 1 to 4 and FIG. 6, the printed circuit board (130) may not be bent except for the area between the first reinforcing plate (140) and the second reinforcing plate (150).

[0053] Specifically, bending may be permitted only in a specific area between the first reinforcing plate (140) and the second reinforcing plate (150) as needed, while the printed circuit board (130) may remain flat in other areas. Through this, the main circuits and electrical connections of the printed circuit board (130) can remain flat without bending. That is, the printed circuit board (130) may not experience electrical contact failures caused by mechanical stress or deformation. By keeping the printed circuit board (130) flat, electrical signal transmission can be accurately achieved even when combined with the busbar (120), which can contribute to increasing the accuracy of battery cell voltage sensing. Additionally, quality issues such as cracks, tears, or electrical contact failures that may occur in the printed circuit board (130) can be reduced. Furthermore, by eliminating unnecessary bending processes, the manufacturing process can be simplified and manufacturing costs can be reduced.

[0054] Figure 7 is a cross-sectional view showing a cross-section cut along the cutting line C-C' of Figure 2.

[0055] Referring to FIGS. 1 to 3 and FIG. 7, the area of ​​the printed circuit board (130) connected to the module connector (170) may be in close contact with the first reinforcing plate (140). The printed circuit board (130) may be connected to the module connector (170). The printed circuit board (130) may transmit voltage data or thermal data of the battery cells to an external BMS through the module connector (170). That is, the module connector (170) according to the present embodiment may be responsible for the function of transmitting voltage information of the battery cells or temperature information inside the battery assembly to the outside. A part of the module connector (170) may be exposed to the outside of the battery assembly. Specifically, the part of the printed circuit board (130) where the module connector (170) is located may be physically in close contact with and fixed to the first reinforcing plate (140), thereby preventing the module connector (170) from moving or being damaged by external shock or vibration. In addition, the electrical connection between the printed circuit board (130) and the module connector (170) can be maintained stably, and the module connector (170) can be protected from physical stress that may occur in the external environment. Furthermore, the structural stability of the printed circuit board (130) is enhanced, which can reduce the defect rate that may occur during the assembly process and improve the quality of the busbar frame assembly (100).

[0056] Referring again to FIGS. 1 to 4, the second reinforcing plate (150) may be closer to the busbar (120) than the first reinforcing plate (140).

[0057] The second reinforcing plate (150) according to the present embodiment is positioned closer to the bus bar (120) than the first reinforcing plate (140) to provide additional support for the printed circuit board (130). The second reinforcing plate (150) is positioned on a plane different from one side of the first reinforcing plate (140) to function to keep a specific area of ​​the printed circuit board (130) flat without bending. Additionally, it can disperse mechanical stress that may occur when the printed circuit board (130) is connected to the bus bar (120) and prevent deformation of the printed circuit board (130). The position of the second reinforcing plate (150) can be designed to stably maintain electrical contact between the printed circuit board (130) and the bus bar (120) and to prevent deformation of the printed circuit board (130) that may occur during the assembly process.

[0058] Referring again to FIGS. 1 to 4, the first reinforcing plate (140) and the second reinforcing plate (150) can be placed on one side of the busbar frame (160).

[0059] The first reinforcing plate (140) and the second reinforcing plate (150) according to the present embodiment help to stably fix the printed circuit board (130) to the busbar frame (160), while simultaneously improving the mechanical strength of the printed circuit board (130). In addition, they can prevent deformation of the printed circuit board (130) that may occur during the assembly process. The first reinforcing plate (140) and the second reinforcing plate (150) may be arranged parallel to one side of the busbar frame (160).

[0060] Additionally, the first reinforcing plate (140), the second reinforcing plate (150), and the printed circuit board (130) can be fixed to the busbar frame (160) by heat fusion bonding. According to the present embodiment, the bonding strength between the printed circuit board (130), the first reinforcing plate (140), the second reinforcing plate (150), and the busbar frame (160) can be significantly increased through heat fusion bonding. This not only simplifies the assembly process but also minimizes mechanical defects that may occur after assembly. Furthermore, the bonded structure can provide strength capable of withstanding external impacts. The temperature during the heat fusion process can be optimized by considering the material of the printed circuit board (130) and the physical properties of the first reinforcing plate (140) and the second reinforcing plate (150), thereby ensuring that the bond between the first reinforcing plate (140), the second reinforcing plate (150), the printed circuit board (130), and the busbar frame (160) is maintained strongly. In addition, the first reinforcing plate (140), the second reinforcing plate (150), and the printed circuit board (130) can be accurately connected to the busbar frame (160), and the connection can be prevented from being released due to external impact or stress.

[0061] According to another embodiment of the present invention, a battery assembly including a busbar frame assembly (100) is provided.

[0062] One or more busbar frame assemblies (100) according to the embodiment described above may be mounted together with a Battery Disconnect Unit (BDU) module for controlling the electrical connection of battery cells and a Battery Management System (BMS) module for monitoring and controlling the operation of battery cells to form a battery assembly. The busbar frame assembly (100) may electrically connect at least one of the battery cells constituting the battery assembly, the battery cells and the BDU module, the battery cells and the BMS module, or the BDU module and the BMS module.

[0063] The busbar frame assembly (100) or battery assembly can be applied to various devices. Specifically, it can be applied to means of transportation such as electric bicycles, electric vehicles, and hybrids, or to an Energy Storage System (ESS), but is not limited thereto and can be applied to various devices that can use secondary batteries.

[0064] In this embodiment, terms indicating directions such as front, back, left, right, up, and down have been used; however, these terms are for convenience of explanation only and may vary depending on the location of the object or the position of the observer.

[0065] Although preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements by those skilled in the art using the basic concept of the present invention as defined in the following claims also fall within the scope of the present invention.

[0066] Explanation of the symbols

[0067] 100: Busbar frame assembly

[0068] 120: Busbar

[0069] 130: Printed circuit board

[0070] 140: First reinforcement plate

[0071] 150: Second reinforcement plate

[0072] 160: Busbar frame

[0073] 170: Module Connector

Claims

1. A busbar connected to multiple battery cells; A printed circuit board (PCB) connected to the busbar for voltage sensing of the above battery cells; A first reinforcing plate and a second reinforcing plate disposed in each of different regions of the above printed circuit board; and A busbar frame assembly comprising: a busbar frame on which the above-mentioned busbar is disposed.

2. In Paragraph 1, A busbar frame assembly in which the second reinforcing plate is separated from the first reinforcing plate and is located on a plane different from one surface of the first reinforcing plate.

3. In Paragraph 1, The above second reinforcing plate is a busbar frame assembly located on the same plane as one side of the busbar.

4. In Paragraph 1, The above printed circuit board is a busbar frame assembly that is in close contact with the first reinforcing plate and the second reinforcing plate.

5. In Paragraph 1, A busbar frame assembly in which the printed circuit board is not bent, except for the area between the first reinforcing plate and the second reinforcing plate.

6. In Paragraph 1, A busbar frame assembly in which the area of ​​the printed circuit board connected to the module connector is in close contact with the first reinforcing plate.

7. In Paragraph 1, The busbar frame assembly, wherein the second reinforcing plate is more adjacent to the busbar than the first reinforcing plate.

8. In Paragraph 1, The first reinforcing plate and the second reinforcing plate are a busbar frame assembly disposed on one side of the busbar frame.

9. In Paragraph 1, A busbar frame assembly in which the first reinforcing plate, the second reinforcing plate, and the printed circuit board are fixed to the busbar frame by heat fusion bonding.

10. A battery assembly comprising a busbar frame assembly according to paragraph 1.

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