Busbar cover and battery pack comprising same

Abstract

According to exemplary embodiments of the present invention, a bus bar cover can be provided. The bus bar cover includes: an inner cover covering a body portion of the bus bar; an outer cover covering the body portion on the inner cover; and a cover cap covering a side portion of the inner cover, wherein the inner cover includes a heat-insulating material, and the outer cover and the cover cap can include at least one from among a fire-resistant material and a heat-resistant material.

Description

Busbar cover and battery pack including the same

[0001] The present invention relates to a busbar cover for a secondary battery and a battery pack including the same.

[0002] This application claims the benefit of Korean application No. 10-2024-0155377, filed on November 5, 2024, which is incorporated herein by reference in its entirety.

[0003] Battery packs applied to electric vehicles and the like have a structure in which multiple battery cell assemblies containing multiple secondary batteries are connected in series or parallel to obtain high output.

[0004] In addition, the above secondary battery is capable of repeated charging and discharging through electrochemical reactions between components including positive and negative current collectors, a separator, an active material, and an electrolyte.

[0005] A busbar is used to electrically connect the above battery cell assemblies. The busbar is used to electrically connect the terminals of adjacent battery cell assemblies or to connect the battery cell assemblies to an external electrical device.

[0006] The problem that the technical concept of the present invention aims to solve is to provide a busbar cover with improved performance and reliability.

[0007] The problem that the technical concept of the present invention aims to solve is to provide a battery pack with improved safety.

[0008] The problem that the technical concept of the present invention aims to solve is to provide a battery pack with improved performance and reliability.

[0009] According to exemplary embodiments of the present invention for solving the above-described problem, a busbar cover may be provided. The busbar cover comprises an inner cover covering a body portion of a busbar; an outer cover covering the body portion on the inner cover; and a cover cap covering a side portion of the inner cover, wherein the inner cover comprises an insulating material, and the outer cover and the cover cap may comprise at least one of a fire-resistant material and a heat-resistant material.

[0010] The above cover cap can further cover the side of the above outer cover.

[0011] The inner cover can be sealed by the outer cover and the cover cap.

[0012] The above cover cap is in the shape of a square ring and can be penetrated by the bus bar.

[0013] The above busbar extends in a first direction, and the busbar further includes a body portion and a contact portion arranged in the first direction, and the cover cap may be configured to be penetrated in the first direction by the contact portion and coupled to the outer cover.

[0014] The contact portions at both ends of the above busbar may not be covered.

[0015] The inner cover may comprise mika, aerogel, or polyurethane (PU) material, and the outer cover may comprise fire resistance barrier (FRB) or non-combustible glass fiber (NCG) material.

[0016] The above outer cover and the above cover cap may be formed as a single unit.

[0017] According to exemplary embodiments of the present invention for solving the above-described problem, a battery pack may be provided. The battery pack comprises: a pack housing; a plurality of battery cell assemblies accommodated in the pack housing; a bus bar extending in a first direction and electrically connecting the plurality of battery cell assemblies; and a bus bar cover, wherein the bus bar cover comprises: an inner cover surrounding a body portion of the bus bar in a second direction intersecting the first direction; an outer cover surrounding the body portion in the second direction on the inner cover; and a cover cap covering a side portion of the inner cover and a side portion of the outer cover and sealing the inner cover, wherein the inner cover comprises an insulating material, and the outer cover and the cover cap may comprise at least one of a fire-resistant material and a heat-resistant material.

[0018] The above cover cap may be configured to have a square ring shape and to be coupled to the outer cover by penetrating in the first direction through the contact portion of the bus bar.

[0019] The above cover cap can overlap with each of the inner cover and the outer cover in the first direction.

[0020] According to exemplary embodiments of the present invention, a busbar cover may include an inner cover comprising an insulating material, an outer cover comprising a fire-resistant and / or heat-resistant material that seals the inner cover, and a cover cap. By doing so, the inner cover is prevented from being exposed to thermal energy outside the busbar, and the thermal energy is prevented from being transferred to the busbar.

[0021] According to exemplary embodiments of the present invention, a busbar cover with improved performance and reliability can be provided.

[0022] According to exemplary embodiments of the present invention, the battery pack may include a busbar cover that covers the busbar. By doing so, the busbar can be protected from heat that may be generated inside the battery pack.

[0023] According to exemplary embodiments of the present invention, a battery pack with improved safety can be provided.

[0024] According to exemplary embodiments of the present invention, a battery pack with improved performance and reliability can be provided.

[0025] The effects obtainable from the exemplary embodiments of the present invention are not limited to those mentioned above, and other unmentioned effects can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of the present disclosure belong from the following description. That is, unintended effects resulting from the implementation of 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.

[0026] FIG. 1 is a perspective view illustrating a busbar cover according to embodiments of the technical concept of the present invention.

[0027] FIG. 2 is a perspective view illustrating the coupling relationship of some components of a busbar cover according to embodiments based on the technical concept of the present invention.

[0028] FIG. 3 is a perspective view of a busbar to explain a busbar cover according to embodiments of the technical concept of the present invention.

[0029] FIG. 4 is a cross-sectional view illustrating a busbar cover according to embodiments of the technical concept of the present invention.

[0030] FIG. 5 is a cross-sectional view illustrating a busbar cover according to embodiments of the technical concept of the present invention.

[0031] FIG. 6 is a perspective view illustrating a busbar cover according to embodiments of the technical concept of the present invention.

[0032] FIG. 7 is a plan view showing a battery pack according to embodiments of the technical concept of the present invention.

[0033] FIG. 8 is a drawing for explaining a battery pack according to embodiments based on the technical concept of the present invention.

[0034] FIG. 9 is a drawing for explaining a battery pack according to embodiments based on the technical concept of the present invention.

[0035] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings. Instead, based on the principle that the inventor can appropriately define the concepts of terms to best describe his invention, they should be interpreted in a meaning and concept consistent with the technical spirit of the present invention.

[0036] Therefore, 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; thus, it should be understood that various equivalents and modifications that can replace them may exist at the time of filing this application.

[0037] In addition, in describing the present invention, if it is determined that a detailed description of related known components or functions may obscure the essence of the invention, such detailed description is omitted.

[0038] Since embodiments of the present invention are provided to more fully explain the invention to those skilled in the art, the shapes and sizes of the components in the drawings may be exaggerated, omitted, or schematically depicted for clearer explanation. Accordingly, the size or proportion of each component does not entirely reflect the actual size or proportion.

[0039]

[0040] (1st embodiment)

[0041] FIG. 1 is a perspective view for explaining a busbar cover (140) according to embodiments of the technical concept of the present invention.

[0042] FIG. 2 is a perspective view for explaining the connection relationship of some components of a busbar cover (140) according to embodiments of the technical concept of the present invention. Specifically, FIG. 2 is a perspective view for explaining the connection of a cover cap (145) of a busbar cover (140).

[0043] FIG. 3 is a perspective view of a busbar (130) for explaining a busbar cover (140) according to embodiments of the technical concept of the present invention.

[0044] FIG. 4 is a cross-sectional view illustrating a busbar cover (140) according to embodiments of the technical concept of the present invention. Specifically, FIG. 4 is a cross-sectional view along line AA of FIG. 1.

[0045] FIG. 5 is a cross-sectional view illustrating a busbar cover (140) according to embodiments of the technical concept of the present invention. Specifically, FIG. 5 is a cross-sectional view along the BB line of FIG. 1.

[0046]

[0047] Referring to FIGS. 1 to 3, a busbar cover (140) covering a busbar (130) may be provided.

[0048] The busbar (130) may have a shape extending in a first direction (D1). The busbar (130) may include a body portion (131) and contact portions (132) at both ends. The contact portions (132) at both ends may be spaced apart from each other in the first direction (D1) with the body portion (131) in between. Each contact portion (132) may include a fastening hole (133) for connecting to another electrical connection portion. The busbar (130) may include a metal conductor such as high-purity copper or aluminum, such as C1100.

[0049] In the embodiments, the busbar cover (140) can cover the body portion (131) of the busbar (130). Specifically, the busbar cover (140) can surround the body portion (131) of the busbar (130) in a second direction (D2) and a third direction (D3). The second direction (D2) and the third direction (D3) can each intersect with the first direction (D1). The busbar cover (140) can overlap the body portion (131) of the busbar (130) in the second direction (D2) and the third direction (D3).

[0050] In the embodiments, the busbar cover (140) may not cover the contact portion (132) of the busbar (130). For example, the busbar cover (140) may not overlap the contact portion (132) of the busbar (130) in the second direction (D2) and the third direction (D3). The contact portion (132) may be exposed by the busbar cover (140).

[0051] Referring to FIGS. 4 and FIGS. 5 together, the busbar cover (140) may include an inner cover (141), an outer cover (143), and a cover cap (145).

[0052] In the embodiments, the inner cover (141) may cover the body portion (131) of the bus bar (130). Specifically, the inner cover (141) may surround the body portion (131) of the bus bar (130) in a second direction (D2) and a third direction (D3). The inner cover (141) may be in close contact with the body portion (131) of the bus bar (130). The inner cover (141) may be in direct contact with the body portion (131) of the bus bar (130) and may surround the four sides extending in the first direction (D1) in the second direction (D2) and the third direction (D3). The inner cover (141) may not be placed on the contact portion (132).

[0053] The inner cover (141) may include an insulating material. Specifically, the inner cover (141) may prevent heat generated outside the busbar (130) from being transferred to the busbar (130). The insulating material refers to a material with low thermal conductivity and may include mika, aerogel, or polyurethane (PU).

[0054] In the embodiments, the outer cover (143) is placed on the inner cover (141) and may surround the inner cover (141). The outer cover (143) may surround the inner cover (141) in a second direction (D2) and a third direction (D3). The outer cover (143) may surround the body portion (131) of the busbar (130) on the inner cover (141) in a second direction (D2) and a third direction (D3). The outer cover (143) may be in close contact with the inner cover (141). The outer cover (143) may be in direct contact with the inner cover (141) and may surround the four sides extending in the first direction (D1) in the second direction (D2) and a third direction (D3). The outer cover (143) may not be placed on the contact portion (132).

[0055] The outer cover (143) may include a fire-resistant and / or heat-resistant material. A fire-resistant and / or heat-resistant material may mean a material whose structure does not deform easily even at high temperatures. For example, a fire-resistant and / or heat-resistant material may mean a material that can maintain its structure at temperatures of 500°C or higher. For example, the outer cover (143) may have a higher density than the inner cover (141) so that its structure does not deform easily even at high temperatures. As a result, it may not deform or be destroyed despite heat or flames that may occur outside the busbar (130).

[0056] The outer cover (143) may include, for example, FRB (fire resistance barrier) or NCG (non-combustible glass fiber) material.

[0057] In the embodiments, the cover cap (145) can cover the sides of the inner cover (141) and the outer cover (143), respectively.

[0058] Specifically, the cover cap (145) may be placed on the side (141_S) of the inner cover (141). For example, the cover cap (145) may overlap the side (141_S) of the inner cover (141) in a first direction (D1). The cover cap (145) may be placed on the side (141_S) of the inner cover (141) that is not covered by the outer cover (143) so as to cover the side (141_S) of the inner cover (141) so that it is not exposed.

[0059] Specifically, the cover cap (145) may also be placed on the side (143_S) of the outer cover (143). For example, the cover cap (145) may overlap the side (143_S) of the outer cover (143) in the first direction (D1). The cover cap (145) may be attached to the outer cover (143) to seal the inner cover (141). By doing so, the inner cover (141) may not be exposed to the outside.

[0060] The cover cap (145) may be made of the same material as the outer cover (143). For example, the cover cap (145) may be made of a fire-resistant and / or heat-resistant material. For example, the cover cap (145) may be made of a fire resistance barrier (FRB) or non-combustible glass fiber (NCG) material.

[0061] As illustrated in FIGS. 1, 2 and 5, the cover cap (145) may include a square ring shape. For example, the cover cap (145) may include a square ring shape that surrounds the bus bar (130) in a second direction (D3) and a third direction (D3). The cover cap (145) may be penetrated by the bus bar (130). The cover cap (145) may be penetrated by the bus bar (130) in a first direction (D1). For example, the cover cap (145) may be configured to be penetrated by the contact portion (132) of the bus bar (130) in a first direction (D1) and coupled to an outer cover (143).

[0062]

[0063] The busbar cover (140) described with reference to FIGS. 1 to 5 covers the busbar (130) and may be composed of an inner cover (141), an outer cover (143), and a cover cap (145). The inner cover (141) may include an insulating material to prevent heat from outside the busbar (130) from being transferred to the busbar (130). The outer cover (143) and the cover cap (145) may include a fire-resistant and / or heat-resistant material to seal the inner cover (141). As the inner cover (141) is sealed by the outer cover (143) and the cover cap (145), the inner cover (141) may be blocked from being exposed to heat and fire from outside the busbar (130), thereby preventing heat from being transferred to the busbar (130).

[0064] According to embodiments of the technical concept of the present invention, a busbar cover (140) with improved performance and reliability may be provided.

[0065]

[0066] (2nd Example)

[0067] FIG. 6 is a perspective view illustrating a busbar cover (140A) according to embodiments of the technical concept of the present invention. Hereinafter, the differences from the busbar cover (140) described with reference to FIG. 1 to 5 will be explained.

[0068] Referring to FIG. 6, a busbar cover (140A) covering a busbar (130) may be provided. The busbar cover (140A) may include an inner cover (not shown), an outer cover (143A), and a cover cap (145A).

[0069] In the embodiments, the outer cover (143A) and the cover cap (145A) may be formed integrally. As described above, the outer cover (143A) and the cover cap (145A) comprise a fire-resistant and / or heat-resistant material and can seal the inner cover. As the outer cover (143A) and the cover cap (145A) are formed integrally, the performance of sealing the inner cover may be improved.

[0070] According to embodiments of the technical concept of the present invention, a busbar cover (140A) with improved performance and reliability may be provided.

[0071]

[0072] (3rd Example)

[0073] FIG. 7 is a plan view showing a battery pack (100) according to embodiments of the technical concept of the present invention.

[0074] FIG. 8 is a drawing for explaining a battery pack (100) according to embodiments of the technical concept of the present invention. Specifically, FIG. 8 is a perspective view of a battery cell assembly (120) of a battery pack (100).

[0075] FIG. 9 is a drawing for explaining a battery pack (100) according to embodiments of the technical concept of the present invention. Specifically, FIG. 9 is a drawing showing a bus bar (130) covered by a bus bar cover (140) being coupled to a battery cell assembly (120) of the battery pack (100).

[0076]

[0077] Referring to FIGS. 7 and 8, the battery pack (100) may include a pack housing (110), a plurality of battery cell assemblies (120), and cross beams (117). The battery pack (100) may be a final product mounted in an application such as a vehicle.

[0078] The pack housing (110) may provide a space for mounting battery cell assemblies (120). The pack housing (110) may include a base plate (111), side walls (112, 113, 114, 115) and a center beam (116).

[0079] Here, the first direction (D1) and the second direction (D2) may be substantially parallel to the mounting surface of the base plate (111) (i.e., the surface facing the battery cell assembly (120)), and the third direction (D3) may be substantially perpendicular to the mounting surface of the base plate (111).

[0080] The side walls (112, 113, 114, 115) may be substantially perpendicular to the base plate (111). The center beam (116) may extend in a first direction (D1). The center beam (116) may be interposed between the side walls (112, 113).

[0081] The base plate (111) may include a plurality of cooling channels. The plurality of cooling channels may provide a passage for the movement of a refrigerant, such as water. The plurality of cooling channels may extend in a first direction (D1). The plurality of cooling channels may be spaced apart in a second direction (D2).

[0082] A plurality of battery cell assemblies (120) may be placed on a base plate (111) of a pack housing (110). The base plate (111) may support the plurality of battery cell assemblies (120). Side walls (112, 113, 114, 115) may horizontally surround the plurality of battery cell assemblies (120). The side walls (112, 113, 114, 115) may protect the plurality of battery cell assemblies (120).

[0083] In FIG. 7, the arrangement of multiple battery cell assemblies (120) can be described as a 3 * 2 arrangement. The arrangement of multiple battery cell assemblies (120) disclosed in FIG. 7 is a non-limiting example and does not limit the technical concept of the present invention in any sense. A person skilled in the art will be able to easily arrive at a plurality of battery cell assemblies (120) arranged in an M * N arrangement (where M and N are each integers greater than or equal to 2) based on what is described herein.

[0084] The battery pack (100) may further include leads coupled to the side walls (112, 113, 114, 115) of the pack housing (110). The leads may cover elements mounted inside the battery pack (100), such as a plurality of battery cell assemblies (120) and electrical components. The leads may be secured to the pack housing (110) by mechanical coupling means, such as bolting.

[0085] The battery pack (100) may further include a Battery Management System (BMS). The BMS may be configured to perform monitoring, balancing, and control of the battery pack (100). Monitoring of the battery pack (100) may include measuring the voltage and current of specific nodes within a plurality of battery cell assemblies (120) and measuring the temperature of set locations within the battery pack (100). The battery pack (100) may include measuring instruments for measuring the voltage, current, and temperature described above.

[0086] Balancing of the battery pack (100) is an operation that reduces deviations between multiple battery cell assemblies (120). Control of the battery pack (100) includes preventing overcharging, over-discharging, and overcurrent. Through monitoring, balancing, and control, the battery pack (100) can operate under optimal conditions, and accordingly, the shortening of the lifespan of each of the multiple battery cell assemblies (120) can be prevented.

[0087] The battery pack (100) may further include additional electrical components such as a cooling device, a Power Relay Assembly (PRA), and a safety plug. The cooling device may include a cooling fan. The cooling fan can prevent overheating of each of the multiple battery cell assemblies (120) by circulating air inside the battery pack (100). The PRA may be configured to supply or cut off power from the high-voltage battery to an external load (e.g., a vehicle motor). The PRA can protect the multiple battery cell assemblies (120) and the external load (e.g., a vehicle motor) by cutting off power supply to the external load (e.g., a vehicle motor) in situations where abnormal voltage, such as a voltage surge, occurs. Additional electrical components may be interposed between the multiple battery cell assemblies (120) and the side wall (115). The space between the battery cell assemblies (120) and the side wall (115) may be referred to as an electrical component mounting area.

[0088] In FIG. 8, the plurality of battery cell assemblies (120) of the battery pack (100) are each illustrated as battery modules, but the technical concept of the present invention is not limited thereto. For example, they may be battery modules having a module housing of a modular structure configured to have at least one side open, or cell blocks in which the entire top, bottom, left, and right sides are open. In this way, according to the technical concept of the present invention, a so-called cell-to-pack structure battery pack (100) composed of cell blocks or battery modules in which all or part of the module housing is omitted can be configured.

[0089] A battery cell assembly (120) may include a module housing (121) and a plurality of battery cells (not shown) inside. The plurality of battery cells are connected to each other as a series and / or parallel circuit so that charging and discharging occur at a specified voltage and current. A pair of high-voltage terminals (122) are provided on the outside of the battery cell assembly (120) as input / output terminals for the electrically connected plurality of battery cells. The pair of high-voltage terminals (122) may be positioned on the front of the module housing (121). The pair of high-voltage terminals (122) may consist of a positive and a negative high-voltage terminal (122).

[0090] A pair of module lifting holes (123) may be provided between a pair of high-voltage terminals (122). Since the battery cell assembly (120) equipped with multiple battery cells is quite heavy, a lifting device is used to perform the operation of storing or removing the battery pack (100). The module lifting holes (123) are provided in the module housing (121) for handling the battery cell assembly (120), and a pair of module lifting holes (123) are provided on the front and rear of the module housing (121) respectively for balance.

[0091] The battery pack (100) may further include a busbar that electrically connects a plurality of battery cell assemblies (120). Specifically, the busbar may be coupled to a high-voltage terminal (122) of each of the plurality of battery cell assemblies (120).

[0092] Specifically, referring to FIG. 9, the busbar (130) can electrically connect a plurality of battery cell assemblies (120) within the battery pack (100). Specifically, the busbar (130) can be electrically coupled to the high-voltage terminal (122) of each of two adjacent battery cell assemblies (120) among the plurality of battery cell assemblies (120). For example, the busbar (130) can be coupled to the high-voltage terminal (122) of the battery cell assembly (120) by fastening a fastening member to the fastening hole (133) of the busbar (130).

[0093] The busbar (130) can be coupled to the battery pack (100) while being covered by the busbar cover (140). For a description of the busbar cover (140) of FIG. 9, refer to FIG. 1 through FIG. 5.

[0094] Specifically, referring to FIGS. 1 to 5 together, a busbar cover (140) covering a busbar (130) of a battery pack (100) may be composed of an inner cover (141), an outer cover (143), and a cover cap (145). The inner cover (141) may include an insulating material, and the outer cover (143) and the cover cap (145) may include a fire-resistant and / or heat-resistant material to seal the inner cover (141).

[0095] Accordingly, the busbar cover (140) can prevent the outer cover (143) and cover cap (145) from being deformed or destroyed even if ignition occurs within the battery pack (100) or heat is generated due to charging and discharging, thereby preventing the inner cover (141) from being exposed to thermal energy. Additionally, the inner cover (141) can prevent heat or fire that may be generated within the battery pack (100) from being transferred to the busbar (130).

[0096] According to embodiments of the technical concept of the present invention, a battery pack (100) with improved performance and reliability can be provided.

[0097] According to embodiments of the technical concept of the present invention, a battery pack (100) with improved safety can be provided.

[0098]

[0099] The present invention has been described in more detail above through drawings and embodiments. However, the configurations described in the drawings or embodiments described in this specification are merely one embodiment of the present invention and do not represent all technical concepts of the present invention; therefore, it should be understood that various equivalents and modifications that can replace them may exist at the time of filing this application.

Claims

1. An inner cover covering the body of the busbar; On the inner cover above, an outer cover covering the body portion; and It includes a cover cap that covers the side of the inner cover, and The above inner cover includes an insulating material, and A busbar cover comprising at least one of a fire-resistant material and a heat-resistant material, wherein the outer cover and the cover cap described above comprise the above-mentioned outer cover and the above-mentioned cover cap.

2. In Paragraph 1, The above cover cap is a busbar cover that further covers the side of the above outer cover.

3. In Paragraph 2, The above inner cover is a busbar cover sealed by the above outer cover and the above cover cap.

4. In Paragraph 1, The above cover cap is in the shape of a square ring and is a busbar cover that is penetrated by the busbar.

5. In Paragraph 4, The above busbar extends in a first direction, and The above busbar further includes the body portion and the contact portion arranged in the first direction, and A busbar cover configured such that the above cover cap is penetrated in the first direction by the contact portion and coupled to the outer cover.

6. In Paragraph 1, A busbar cover that does not cover the contact portions at both ends of the busbar.

7. In Paragraph 1, The above inner cover comprises mika, aerogel, or polyurethane (PU) material, and The above outer cover is a busbar cover comprising FRB (fire resistance barrier) or NCG (non-combustible glass fiber) material.

8. In Paragraph 1, A busbar cover in which the outer cover and the cover cap are integrally formed.

9. Pack Housing; A plurality of battery cell assemblies accommodated in the above-mentioned pack housing; A busbar electrically connecting the plurality of battery cell assemblies and extending in a first direction; and Includes busbar cover, The above busbar cover is, An inner cover surrounding the body portion of the busbar in a second direction intersecting the first direction; On the inner cover above, an outer cover surrounding the body portion in the second direction; and It includes a cover cap that covers the side of the inner cover and the side of the outer cover and seals the inner cover. The above inner cover includes an insulating material, and A battery pack wherein the outer cover and the cover cap comprise at least one of a fire-resistant material and a heat-resistant material.

10. In Paragraph 9, A battery pack configured such that the above cover cap is in the shape of a square ring and is penetrated in the first direction by the contact portion of the bus bar to be coupled to the outer cover.

11. In Paragraph 9, A battery pack, wherein the cover cap overlaps the inner cover and the outer cover, respectively, in the first direction.

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