Secondary battery

A secondary battery includes an electrode assembly in which a cathode plate and an anode plate are arranged with a separator being interposed therebetween, a case in which the electrode assembly is received, a cap assembly capable of sealing an open end of the case, a gasket interposed between the case and the cap assembly, and a leakage prevention portion formed at one surface of the gasket and/or one surface of the cap assembly, which is oriented toward the electrode assembly and contacted with the gasket.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 USC 119(a) to Korean Patent Application No. 10-2010-0023887 filed in Republic of Korea on Mar. 17, 2010, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a secondary battery, and more particularly to a lithium ion/polymer secondary battery.

2. Description of the Related Art

Generally, secondary batteries are rechargeable batteries, differently from primary batteries, and such secondary batteries are widely used as power sources of electric vehicles or electronic devices such as cellular phones, notebooks and camcorders. In particular, a capacity of a lithium secondary battery with an operation voltage of 3.6V is about three times or more of that of nickel-cadmium batteries or nickel-hydrogen batteries frequently used as power source of electronic devices. In addition, the lithium secondary battery has a high energy density per unit weight, so lithium secondary batteries tend to be more increasingly used.

The lithium secondary battery frequently uses lithium-based oxides and carbon materials as positive active material and negative active material, respectively. Also, the lithium secondary battery may be classified into rectangular cells, cylindrical cells and pouch-type cells.

The lithium ion secondary battery includes an electrode assembly in which a positive electrode, a separator and a negative electrode are arranged in order, and an enclosure sealing the electrode assembly together with electrolyte. In particular, an enclosure of a rectangular-type or cylindrical-type secondary battery includes a case having an open end and a cap assembly sealing the open end of the case.

The electrode assembly is classified into a jelly-roll type electrode assembly in which a separator is interposed between sheet-type positive and negative electrodes respectively coated with active materials and then rolled, and a stack-type electrode assembly in which a separator is interposed between positive and negative electrodes of a predetermined size such that they are stacked in order. Here, the jelly-roll type electrode assembly is widely used since the jelly-roll type electrode assembly is advantageous in easy production and high energy density per weight and is easily received in a cylindrical or rectangular case. Meanwhile, the stack-type electrode assembly is widely used as pouch-type batteries.

However, when a secondary battery is charged/discharged, the electrode assembly tends to be deformed through repeated expansion and shrinkage, and in this procedure, in case of the jelly-roll type electrode assembly, stress is focused on a metallic center pin, so electrodes may pierce into the separator and come into contact with the metallic center pin, which causes internal electric short circuit. Such an internal short circuit of the secondary battery makes the battery generate heat, and the heat may decompose organic solvent to generate gas, thereby increasing the pressure in the battery and rupturing the enclosure. The gas pressure in the battery may also be increased due to internal short circuit caused by an external impact.

In order to solve such a safety-related problem of a battery, the secondary battery is basically provided with a PTC element. In particular, a cylindrical secondary battery includes a cap assembly that includes safety devices such as a safety vent for discharging a high-pressure gas and a CID (Current Interrupt Device) for interrupting an electric current when an inner pressure of the battery is increased, and a top cap for forming a protruded terminal protecting such safety devices. Also, the cap assembly is sealed with the case by means of a gasket.

However, in such a conventional secondary battery, while the cap assembly is assembled with the case by means of the gasket, the possibility of creation of a gap is very high between the gasket and the cap assembly or between the gasket and the case. Such a gap deteriorates sealing of the battery. In other words, the gasket is compressed and deformed due to the case during a clamping process or the like, so the case is closely adhered to the cap assembly. However, in the gasket adopting a conventional structure, a surface closely adhered between the case and the cap assembly has a simple flat shape, so its sealing ability is not so good. In particular, if the clamping surface of the gasket is not uniformly pressed while the case is clamped, the flat surface of the gasket is deformed unevenly, so the gasket is partially not adhered to the case or the cap assembly, thereby creating a gap and thus deteriorating the sealing with the case.

In order to solve this problem, Korean Patent Publication No. 10-2006-0037595 discloses a secondary battery having at least one wrinkle with an uneven shape formed at a surface of a gasket, which is contacted with a case and a cap assembly. However, this secondary battery has an uneven structure only at the gasket made of plastic, so the deterioration of sealing of the secondary battery is still not overcome. The sealing structure of such a gasket of the conventional secondary battery is designed for sealing the interface portion between the safety vent located at a primarily exposed portion of electrolyte and/or gas, or a lowermost layer of the cap assembly, and the gasket surrounding an outer periphery of the safety vent, so the above problem occurs. In other words, in the sealing manner disclosed in the conventional document, in a state that electrolyte or the like is leaked through the interface between the safety vent and the gasket surrounding the outer periphery of the safety vent, a final end of the interface is sealed. Thus, the sealing structure between the cap assembly and the gasket according to the conventional technique has an obvious limit.

SUMMARY OF THE INVENTION

The present invention is designed to solve the problems of the prior art, and therefore it is an object of the present invention to provide a secondary battery having an improved structure such that a portion where electrolyte and/or is initially leaked, or an interface between a gasket and a cap assembly having a safety vent, is sealed in a more perfect way.

In one aspect of the present invention, there is provided a secondary battery, which includes an electrode assembly in which a cathode plate and an anode plate are arranged with a separator being interposed therebetween; a case in which the electrode assembly is received; a cap assembly capable of sealing an open end of the case; a gasket interposed between the case and the cap assembly; and a leakage prevention portion formed at one surface of the gasket and/or one surface of the cap assembly, which is oriented toward the electrode assembly and contacted with the gasket.

Preferably, the cap assembly includes a top cap configured to seal the open end of the case; a PTC (Positive Temperature Coefficient) element arranged in contact with the top cap; and a safety vent having one side contacted with the PTC element and the other side contacted with the gasket, the leakage prevention portion being formed at the other side of the safety vent, the safety vent being electrically connected to the electrode assembly.

Preferably, the leakage prevention portion includes at least one serration or protrusion formed at the surface of the cap assembly contacted with the gasket.

Preferably, the serration has a triangular, rectangular, circular or round shape.

Preferably, the protrusion has a triangular or quadrangular pyramid shape.

Preferably, the serration or protrusion further includes a barb.

Preferably, the safety vent is made of metallic material.

Preferably, the secondary battery further includes a second leakage prevention portion formed at a surface of the cap assembly, which is opposite to the leakage prevention portion and contacted with the gasket.

Preferably, the secondary battery further includes a third leakage prevention portion formed at a surface of the cap assembly, which is contacted with the gasket.

Preferably, at least one of the second leakage prevention portion and the third leakage prevention portion has at least one serration or protrusion.

Preferably, at least one of the leakage prevention portion and the third leakage prevention portion has at least one serration or protrusion.

The secondary battery according to the present invention is configured such that a serration or protrusion is provided at a portion where electrolyte or gas is initially leaked, or at one surface of at least one of a cap assembly in which a top-cap, a PTC element and a safety vent are arranged in order and a gasket contacting with the cap assembly, thereby enhancing a coupling force between the cap assembly and the gasket. In addition, since a moving length of the pass of gas or electrolyte through the portion is increased, a sealed state of the secondary battery is greatly improved though an external impact is applied thereto or though an inner pressure of the secondary battery is increased.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A secondary battery according to a preferred embodiment of the present invention includes an electrode assembly in which a cathode plate and an anode plate are arranged with a separator being interposed therebetween, a case in which the electrode assembly is received, a cap assembly capable of sealing an open end of the case, a gasket interposed between the case and the cap assembly, and a leakage prevention portion formed at one surface of the gasket and/or one surface of the cap assembly, which is oriented toward the electrode assembly and contacted with the gasket.

The cap assembly includes a top cap configured to seal the open end of the case, a PTC (Positive Temperature Coefficient) element arranged in contact with the top cap, and a safety vent having one side contacted with the PTC element and the other side contacted with the gasket, the leakage prevention portion being formed at the other side of the safety vent, the safety vent being electrically connected to the electrode assembly.

An interface portion between the cap assembly and the gasket, particularly an interface portion between the gasket and the safety vent, may easily leak electrolyte or gas, so the leakage prevention portion formed as above may prevent electrolyte or gas from being leaked at the interface until the safety vent is short-circuited, thereby greatly improving the safety of the battery.

The leakage prevention portion includes at least one serration or protrusion formed at the surface of the cap assembly, which is contacted with the gasket. Meanwhile, the leakage prevention portion having a serrated or protruded structure improves a coupling force between the cap assembly and the gasket when the cap assembly is assembled to the case of the battery via the gasket by means of a mechanical pressing process (or, a clamping process). In detail, due to the leakage prevention portion having a serrated or protruded structure, a serration or protrusion of the safety vent made of metallic material partially pierces through a surface of the gasket made of plastic, and thus a coupling force between the cap assembly and the gasket, assembled as above, is greatly enhanced.

The leakage prevention portion having a serrated or protruded structure may be formed at the surface of the cap assembly, contacted with the gasket, and/or the surface of the gasket, contacted with the cap assembly. In aspect of the coupling force, it is preferred that protrusions or serration are formed at both surfaces. The leakage prevention portion with a serrated or protruded structure has no special limit in its location, size and shape if it can enhance a coupling force between the gasket and the cap assembly. However, the leakage prevention portion having a serrated structure preferably has a triangular, rectangular, circular or round shape, and the leakage prevention portion having a protruded structure preferably has a triangular or quadrangular pyramid shape. The triangular or quadrangular pyramid-shape protrusion with a sharp tip is preferably formed at the safety vent, and such a protrusion may easily pierce through the surface of the gasket, thereby improving a coupling force, an adhering (or, fixing) property and a shape-fitting ability of the contacting interfaces. In addition, the leakage prevention portion with a protruded structure preferably has a barb, like one commonly formed at a fish hook, at a tip of the protruded structure so as to further improve a coupling force and/or an adhering property of the interface.

A secondary battery according to another embodiment of the present invention further includes a second leakage prevention portion formed at a surface of the cap assembly, which is opposite to the leakage prevention portion and contacted with the gasket. The leakage prevention portion primarily prevents electrolyte or gas from being leaked, but if the leakage preventing ability of the leakage prevention portion is insufficient, the second leakage prevention portion secondarily functions to prevent leakage of electrolyte or gas. The second leakage prevention portion has the same shape and structure as the leakage prevention portion.

A secondary battery according to still another embodiment of the present invention further includes a third leakage prevention portion formed at any one of the surface of the case, which is contacted with the gasket, and the surface of the gasket, which is contacted with the case. The third leakage prevention portion is used for preventing electrolyte or gas from being leaked through the interface between the case and the gasket, separately from the leakage prevention portion and the second leakage prevention portion explained above.

The safety vent is preferably made of metallic material. The size of the safety vent may be changed in accordance with its material and structure, and there is no special limitation if the safety vent may be ruptured to discharge gas when high pressure of a certain level is generated in the battery. In particular, the safety vent may have a thickness of about 0.2 to 0.6 mm.

Thickness of the PTC element may also be changed depending on its material or structure, and preferably 0.2 to 0.4 mm. However, if the PTC element has too great thickness, internal resistance is increased, and thus the size of the battery is also increased, which decreases the capacity of battery per unit size. If the PTC element has too small thickness on the contrary, it is difficult to intercept a current at high temperature as desired, and the PTC element may be broken even by a weak external impact. Thus, the thickness of the PTC element may be suitably determined within the above range in consideration of the above factors together.

The top cap contacted with the PTC element has no special limit in its thickness if the top cap may protect various components of the cap assembly against a pressure applied from the outside, and the thickness of the top cap is preferably 0.3 to 0.5 mm. If the top cap has too small thickness, the top cap may not easily exhibit a suitable mechanical strength. If the top cap has too great thickness on the contrary, size and weight of the battery are increased, so the capacity of battery per unit size may be decreased undesirably.

The gasket is made of elastic material with electric insulation, which is not specially limited if it has electric insulation, impact resistance, elasticity and durability. For example, the gasket may be made of polyolefin or polypropylene (PP).

Generally, in a cylindrical secondary battery, a cathode lead welded to a cathode foil of a jelly-roll type electrode assembly is electrically connected to the cap assembly and connected to a protruded terminal at the upper end of the top cap, and an anode lead welded to an anode foil is welded to a sealed end of the case such that the case itself configures an anode terminal. The material of the case is not specially limited, but the case may be made of any one of stainless steel, steel and aluminum, or their equivalents. In a state that the electrode assembly is received in the case, an electrolytic solution is injected therein, and the cap assembly is mounted to an open end of the case to seal the open end, and then the secondary battery is completely assembled.

The secondary battery according to the embodiments of the present invention may be a lithium (ion) secondary battery having high energy density, high discharge voltage and excellent power stability. The lithium secondary battery may be composed of a cathode, an anode, a separator and a nonaqueous electrolytic solution containing lithium salt. The cathode is for example made by coating a cathode current collector with a mixture of cathode active material, conductive material and binder and then drying it, and, if necessary, filler is further added thereto. The anode is made by coating an anode current collector with anode active material and then drying it, and the above components may be further included therein as necessary. The separator is interposed between the anode and the cathode and made of a thin insulating film with excellent ion transport and excellent mechanical strength. The nonaqueous electrolytic solution containing lithium salt is composed of nonaqueous electrolyte and lithium salt. The nonaqueous electrolyte is liquid nonaqueous electrolyte, solid electrolyte or inorganic solid electrolyte. Here, the current collector, the electrode active material, the conductive material, the binder, the filler, the separator, the electrolytic solution and the lithium salt are well known in the art and thus not explained in detail here.

Hereinafter, a secondary battery according to a preferred embodiment of the present invention is explained with reference to the accompanying drawings.

FIG. 1is a sectional view schematically showing configuration of the secondary battery according to the preferred embodiment of the present invention.

Referring toFIG. 1, the secondary battery100of this embodiment includes a cylindrical case20in which an electrode assembly10is received together with electrolyte, a cap assembly30coupled to seal an open end of the case20, a gasket40interposed between the case20and the cap assembly30, and a leakage prevention portion50formed at both a surface of the cap assembly30, which is oriented toward the electrode assembly10, and a surface of the gasket40, which is contacted with the surface of the cap assembly30.

The electrode assembly10includes two electrode plates11having different polarities and having a roll-type wide plate shape, and a separator12interposed between the electrode plates11or disposed at a right or left side of any one of the electrode plates11so as to insulate the electrode plates11from each other. The electrode assembly10preferably has a rolled structure of a so-called ‘jelly-roll’ type. It is also possible that cathode and anode plates of a predetermined size are laminated with a separator being interposed between them. For making two electrode plates11, a current collector made of a metallic foil or mesh containing aluminum and copper, respectively, is coated with active material slurry. The slurry is generally obtained by stirring granular active material, auxiliary conductor, binder and plasticizer, which are added to a solvent. The solvent is removed in a following process. The electrode plate11preferably has non-coating portions that are not coated with the slurry, at an initiating end and a finishing end of the current collector in a direction that the electrode plate11is rolled. A pair of leads corresponding to the electrode plates11respectively are attached to the non-coating portions. A first lead13attached to an upper end of the electrode assembly10is electrically connected to the cap assembly30, and a second lead (not shown) attached to a lower end of the electrode assembly10is connected to a bottom of the case20. It is also possible that both of the first lead13and the second lead are drawn toward the cap assembly30.

The electrode assembly10is disposed on a first insulation plate (not shown) installed at the bottom of the case20, and a second insulation plate14is preferably disposed at an upper end of the electrode assembly10. The first insulation plate insulates the electrode assembly10from the bottom of the case20, and the second insulation plate14insulates the electrode assembly10from the cap assembly30.

The case20is made of light conductive metallic material such as aluminum or aluminum alloys, and the case20has a cylindrical structure having an open portion at its upper end and a closed bottom opposite thereto. The electrode assembly10and an electrolytic solution (not shown) are received in an inner space of the case20. The electrolytic solution is used for transferring lithium ions generated by electric and chemical reactions of the electrode plates11when the secondary battery100is charged/discharged. The electrolytic solution may be a nonaqueous organic electrolyte that is a mixture of lithium salt and organic solvent, or a polymer using polymer electrolyte, but the kind of electrolyte is not specially limited.

Meanwhile, a metallic center pin (not shown) may be inserted at a center of the case20so as to prevent the electrode assembly10rolled into a jelly-roll type from being released and to play a role of gas passage in the secondary battery100. An upper portion of the case20above the electrode assembly10is bent inwards by pressure to form a beading portion24for preventing vertical movement of the electrode assembly10.

The cap assembly30is assembled to the open end of the case20in a state that the cap assembly30is sealed by means of the gasket40. The cap assembly30includes a top cap32, a PTC element34, a safety vent36and a CID (Current Interrupt Device)38. The top cap32has an electrode terminal (not shown) formed for electric connection with an external device. The PTC element34is used for intercepting flow of current in the battery when the battery100is overheated. The safety vent36is protruded convexly at its center and welded to the CID38. The CID38may be deformed together with the safety vent36due to the inner pressure of the secondary battery100, and the CID38may be classified into CID gasket and CID filter.

The gasket40generally has a cylindrical shape with both ends opened, and one end of the gasket40is preferably bent at a right angle toward the center such that the one end is located at an open portion of the case20, or a clamping portion. The other end of the gasket40is spread straightly at an initial assembling stage toward an axial direction of the cylindrical gasket40, and the other end of the gasket40is bent at a right angle toward the center during a pressing process such that inner and outer peripheries of the gasket40are respectively closely adhered to the top cap of the cap assembly30and the inner side of the case20. The gasket40is made of material having electric insulation, impact resistance, elasticity and durability, for example polyolefin or polypropylene (PP).

The leakage prevention portion50is formed at the lower surface of the safety vent36and the surface of the gasket40, which is contacted with the safety vent36, and the leakage prevention portion50has a serrated structure whose side is triangular. In other words, the serration prepared at the safety vent36and the serration prepared at the gasket40are engaged with and closely adhered to each other when the open end of the case20is clamped, thereby further enhancing a sealing and coupling force between the cap assembly30and the gasket40. Thus, the leakage prevention portion50prevents electrolyte or gas from being leaked above the cap assembly30until the safety vent36is ruptured, in case an inner pressure of the secondary battery is increased.

FIG. 2is a sectional view showing a cap assembly of a secondary battery according to another embodiment of the present invention. The same reference symbol as inFIG. 1designates the same component with the same function.

Referring toFIG. 2, the secondary battery100of this embodiment has a leakage prevention portion60having a rectangular shape. The leakage prevention portion60has a rectangular serrated structure formed at contact portions between the safety vent36and the gasket40. The leakage prevention portion60increases a moving distance of electrolyte or gas rather than the above leakage prevention portion50, thereby greatly improving a sealing of the interface though an external impact or inner pressure is increased.

FIGS. 3 and 4are sectional views showing secondary batteries according to other embodiments of the present invention. The same reference symbol as inFIGS. 1 and 2designates the same component with the same function.

Referring toFIGS. 3 and 4, the secondary battery of these embodiments includes a circular leakage prevention portion70or a round leakage prevention portion80. The leakage prevention portion70shown inFIG. 3is prepared at an interface where the safety vent36and the gasket40contact each other, and semicircular convex and concave parts are successively formed at the leakage prevention portion70, and the convex and concave parts at the interface are respectively engaged with corresponding concave and convex parts. The leakage prevention portion80shown inFIG. 4is prepared at an interface where the safety vent36and the gasket40contact each other, and round convex and concave parts are successively formed at the leakage prevention portion80, and the convex and concave parts at the interface are respectively engaged with corresponding concave and convex parts.

FIG. 5is a sectional view showing a cap assembly of a secondary battery according to another embodiment of the present invention. The same reference symbol as inFIGS. 1 to 4designates the same component with the same function.

Referring toFIG. 5, the secondary battery200of this embodiment further includes a second leakage prevention portion150in addition the aforementioned leakage prevention portion50.

The second leakage prevention portion150has a protruded structure prepared at an upper surface of the top cap32. This protruded structure may have a triangular or quadrangular pyramid shape. The protruded region of the second leakage prevention portion150pierces into the surface of the gasket40and is coupled with the gasket40when the case20and the cap assembly30are clamped, thereby increasing a coupling force and a sealing property between the gasket40and the top cap32. The protruded structure of the second leakage prevention portion150may be deformed, and in this case, a serration may be formed at a corresponding surface of the gasket40.

FIG. 6is a sectional view schematically showing a modification of the cap assembly shown inFIG. 5. The same reference symbol as inFIGS. 1 to 5designates the same component with the same function.

Referring toFIG. 6, a cap assembly30′ of the secondary battery200according to this embodiment includes a leakage prevention portion50′ formed at a lower surface of the safety vent36and having a protruded shape, and a second leakage prevention portion150′ formed at an upper surface of the tap cap32and having a protruded shape, wherein protrusions52,152of the leakage prevention portions50′,150′ further include barbs54,154formed at their tips, respectively. Such barbs54,154are more firmly secured to the gasket40when the protrusions52,152pierces into the gasket40while the gasket40and the cap assembly30are coupled by means of the case20during the clamping process, thereby enhancing a coupling force and a sealing force.

FIG. 7is a sectional view schematically showing a cap assembly of a secondary battery according to another embodiment to the present invention. The same reference symbol as inFIGS. 1 to 6designates the same component with the same function.

The secondary battery300of this embodiment further includes a third leakage prevention portion250in addition to the aforementioned leakage prevention portion50and the second leakage prevention portion150.

The third leakage prevention portion250has a protruded or serrated structure formed at an inner side of the case20, which is contacted with the gasket40. As a modification, a serration or protrusion may also be prepared at a surface of the gasket40in correspondence with the protruded or serrated structure of the case20. The third leakage prevention portion250is used for preventing electrolyte or gas from being discharged through a portion other than the interface between the gasket40and the cap assembly30, or through an inner side of the case20, due to an external impact or inner pressure in the battery.

Free Fall Experiment

Ten (10) samples of the secondary battery (a comparative example 1) having a serration only at the gasket were prepared, and 20 samples of the secondary battery (an experimental example 1) having serrations at both the gasket and the safety vent were prepared. The samples had fallen from a 1 m height to a concrete bottom 10 times, respectively. After the experiment, it was found that electrolyte was leaked from the samples of the comparative example at 2.1 free falls on average, and that electrolyte was not leaked from 20 samples of the experimental example 1 even at 10 free falls.

Results of the experiment are depicted in the following table 1.

Pressure Experiment

Holes are formed at bottoms of the secondary battery samples, and nitrogen gas was injected through the holes to increase an inner pressure of the samples.

As a result of the experiment, leakage was found at the 20 samples of a secondary battery (a comparative example 2) having a serration only at the gasket until the CID is short-circuited, and leakage was found only at three samples when the CID was short-circuited, namely at a pressure of about 12 kgf/cm2.

In case of 20 samples of a secondary battery (an experimental example 2) having serrations at both the gasket and the safety vent, leakage was not found though a pressure was increased to 16 kgf/cm2after the CID was short-circuited.

The results of experiment are depicted in the following table 2.