BATTERY MODULE

A battery module comprising a first cell having a first electrode terminal, a second cell having a second electrode terminal, and the first electrode terminal and the second electrode terminal forming an electrode terminal set; at least one bus bar having a bus bar contact surface, a support provided on one side of the first and second cells, and at least one cover clip that engages into the support to sandwich the electrode terminal set and the bus bar contact surface to prevent separation of contact between at least one of (a) the first and second electrode terminals or (b) the bus bar contact surface and the electrode terminal set.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of Korean Patent Application No. 10-2017-0083631, filed in Korea on Jun. 30, 2017 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

The present disclosure relates to a battery module, and more particularly to a battery module in which battery cells are detachably coupled to the battery module.

Vehicles that are designed to generate driving force from engines using fossil fuels are problematic in that they cause air pollution. In order to overcome this problem, there is proposed a technology in which a secondary battery capable of being charged and discharged is used as the power source of a vehicle. In recent years, an electric vehicle (EV) capable of being operated using only a battery, a hybrid electric vehicle (HEV) capable of being operated using a combination of a battery and an existing engine have been developed and commercialized. As a secondary battery serving as a power source of an electric vehicle, a hybrid electric vehicle and the like, a nickel-metal-hydride battery, a lithium-ion battery or the like is used.

Since a high-output and high-capacity battery is required in order to be used as a power source of an electric vehicle, a hybrid electric vehicle or the like, a medium and large-sized battery module in which a large number of small-sized secondary batteries (unit batteries) are connected to each other in series and/or in parallel has been used. Laser welding, ultrasonic welding or the like is used in a process of connecting small-sized secondary batteries (unit batteries) in series and/or in parallel.

However, in the case of a battery module composed of a large number of small-sized secondary batteries which are connected to each other by using, for example, welding, when a problem occurs in one among the large number of small-sized secondary batteries constituting the battery module, the entire battery module may require replacement with a new battery module because it is not possible to remove only the problematic small-sized secondary battery.

DETAILED DESCRIPTION

Referring toFIG. 1, a vehicle1according to an embodiment of the present may include a motor5for generating power required to drive the vehicle1. The motor5is operated by electrical energy supplied from a battery pack10, and is able to convert the electrical energy into kinetic energy.

The vehicle1may include the battery pack10for generating electrical energy. The battery pack10may be positioned at the center of the bottom of the vehicle body. However, other locations may be possible.

The battery pack10may be disposed between a front rotating shaft and a rear rotating shaft of the vehicle1. The bottom of the vehicle body may be disposed at the lower side of the vehicle interior. The vehicle interior may be provided with an instrument panel, a center console box and a sheet. The battery pack10may be disposed outside the vehicle interior, and the battery pack10may be disposed at a lower portion of the bottom of the vehicle body. The battery pack10may serve to replace a fuel tank of an internal-combustion vehicle. The battery pack10may be charged to increase energy stored or discharged to decrease energy stored in the battery pack10. The battery pack10may generate heat during charging and discharging.

Referring toFIG. 2, the battery pack10may include a casing20defining the appearance of the battery pack10. The casing20may include a cover21coupled to a tray22so as to cover the battery module100. The casing20may include the tray22for supporting the load of the battery module100. The casing20may include support panels25, which are intended to increase rigidity of the tray22and to uniformly distribute the load of a heat sink40to the tray22.

The battery pack10may include the heat sink40in which cooling water, cooling water with additive or other coolant, absorbing heat energy generated from the battery module100, flows. The heat sink40is made of a material having a high coefficient of heat transfer, and allows cooling water or other coolant to flow therein.

The battery pack10may include thermal pads60for transferring heat energy from the battery module100to the heat sink40. The thermal pads60may be thermal conductive pads. The thermal pads60may be made of a material having high heat conductivity. The battery pack10may also include brackets80.

The battery pack10may include the battery module100having battery cells for generating electrical energy. The battery module100may include a plurality of battery modules contained in the battery pack10. The battery pack10may be configured such that the plurality of battery modules100are electrically connected to each other. The battery pack10may be configured such that the plurality of battery modules100are disposed on the same plane. The battery pack10may be configured such that the plurality of battery modules100are arranged one above the other.

The battery module100according to an embodiment of the present disclosure will be described with reference toFIGS. 3 to 10. The battery module100may include a plurality of battery cells130, which are stacked one on each other. Each of the battery cells130may include an electrode terminal133(including133a,133bfor example), which is protruded and bent in one direction. The battery module100may include bus bars150, each of which functions to electrically connect adjacent bent electrode terminals of the battery cells130. The battery module100may include a circuit board140, which is disposed at a first side of the plurality of battery cells130and which includes voltage terminals through which voltage is input and output. The battery module100may include cover clips160, which are coupled to the circuit board140so as to bring the bent electrode terminals133into contact with the bus bars150so as to sandwich the bent electrode terminals, or electrode terminal set, and bus bar contact surfaces, of the bus bars, to prevent separation of or maintain contact between.

Referring toFIG. 3, the battery module100may be configured to have a rectangular parallelepiped shape overall. A plurality of battery modules100may be disposed in the battery pack10. The plurality of battery modules100may be disposed in the same plane in the battery pack10. The plurality of battery modules100may be disposed one over the other in the battery pack10.

The battery module100may include a cartridge cover110for covering at least one side of the stacked body or stack in which a plurality of cell cartridges120are stacked. The cartridge cover110may cover opposite sides of the stacked body of the plurality of cell cartridges120. Specifically, the cartridge cover110may cover opposite sides of the stacked body in the direction in which the plurality of cell cartridges120are stacked.

A pair of cartridge covers110may cover the opposite sides of the stacked body in the direction in which the plurality of cell cartridges120are stacked. The pair of cartridge covers110may cover opposite sides of the stacked body in the direction in which the plurality of cell cartridges120are stacked. The cartridge cover110may protect the cell cartridges120from external shocks. The cartridge cover110may also prevent foreign matter from entering the cell cartridges120.

The cartridge cover110may be coupled to the cell cartridge120. The cartridge cover110may be coupled to the cell cartridge120by using, for example, coupling elements. The cartridge cover110may be fastened to the cell cartridge120by using, for example, fastening elements or fasteners. The cartridge cover110may be configured to provide coupling force to the plurality of cell cartridges120.

One of the cartridge cover110and the cell cartridge120may be provided with a protrusion while the other of the cartridge cover110and the cell cartridge120may be provided with a recess corresponding to the protrusion in order to increase the coupling force between the cartridge cover110and the cell cartridge120.

The cell cartridge120may be configured to have a rectangular parallelepiped shape. The cell cartridge120may be made of a material having high thermal conductivity, which may efficiently transfer the heat generated from the battery cell130to the outside of the cell cartridge120.

The cell cartridge120may have a space for accommodating the battery cell130. The cell cartridge120may accommodate at least one battery cell130therein. In the embodiment, the cell cartridge120accommodates two battery cells130therein. However, the cell cartridge120may also accommodate three or more battery cells130.

The cell cartridge120may be provided with a thermal interface material (TIM) for improving thermal conductivity, in which the thermal interface material is provided on the surface of the cell cartridge120that the battery cell130contacts. The cell cartridge120may be configured to be open on at least one side thereof. In the embodiment, the cell cartridge120is open at opposite sides thereof. However, the cell cartridge120may be configured to be open only on one side thereof.

The cell cartridge120may be composed of a plurality of cell cartridges120, which are stacked one on each other. The plurality of cell cartridges120may be configured to have shapes engaging with each other such that the plurality of cell cartridges120are stacked one on each other in an engaging manner.

The cell cartridge120may be disposed to be able to contact the cartridge cover110. The cell cartridge120may be covered on at least one side thereof with the cartridge cover110. The cell cartridge120may be covered on opposite sides thereof with the cartridge cover110. The cell cartridge120may be covered at opposite sides thereof with the cartridge cover110in the direction in which the plurality of cell cartridges120are stacked. The battery cell130may generate electrical energy by virtue of a chemical reaction. The battery cell130may be of a pouch cell.

At least one battery cell130may be accommodated in the cell cartridge120. In the embodiment, two battery cells130are accommodated in the cell cartridge120. However, three or more battery cells130may also be accommodated in the cell cartridge120.

The battery cell130may be composed of a plurality of battery cells, which are stacked one on each other. The plurality of battery cells130may be electrically connected to each other.

Referring toFIG. 4, the battery cell130may include a cell body131, which generates electrical energy therein. The cell body131may be accommodated in the cell cartridge120.

The cell body131may include an electrode terminal133for supplying electrical energy generated therein to the outside of the cell body131. The cell body131may include the electrode terminal133protruding toward at least one side. The cell body131may include the electrode terminal133protruding to the left and/or right. In the embodiment, the cell body131may include electrode terminals133that respectively protrude to the left and right.

The electrode terminal133may electrically connect adjacent battery cells130to each other. Referring toFIG. 5, the electrode terminal133may be bent at least once. The electrode terminal133may transfer electrical energy in the battery cell130to the outside of the battery cell130.

The electrode terminals133of different cell bodies131may be brought into contact with each other, and may thus be electrically connected to each other. The electrode terminals133of a plurality of adjacent cell bodies131are electrically connected to each other, and may be connected to each other in series in order to generate resultant power. The electrode terminals133of a plurality of adjacent cell bodies131are electrically connected to each other, and may be connected to each other in parallel so as to generate the resultant power.

Referring toFIG. 5, a plurality of bent electrode terminals133may penetrate the circuit board140, and may be disposed between the circuit board140and the cover clips160in a stacked state. The length that the electrode terminal133protrudes may be set such that the electrode terminal133contacts the bus bar150at a predetermined surface area thereof. The plurality of electrode terminals133may be the same length. The plurality of electrode terminals133may be different lengths. The plurality of electrode terminals133may be configured in such a manner that the electrode terminal133that is first stacked has a length shorter than an electrode terminal133that is subsequently stacked on the first electrode terminal133, which may enhance and/or improve contact efficiency between the plurality of electrode terminals133.

The electrode terminal133may protrude through an electrode terminal passage hole142(including142a,142bfor example) formed in the circuit board140. The plurality of electrode terminals133may be stacked or overlapped on the bus bars150disposed on the circuit board140.

The electrode terminals133may be stacked in such a manner that one bent electrode terminal133is disposed on the bus bar150and another bent electrode terminal133is then stacked on the previous bent electrode terminal133so as to form an area that overlaps the previous bent electrode terminal133.

The electrode terminal133may be provided with an electrode terminal hole135into which a boss145(including145a,145bfor example) is fitted. The electrode terminal hole135may be configured to have a size corresponding to the size of the boss145. The electrode hole135may be composed of a plurality of electrode terminal holes, which are arranged vertically.

The boss145may be fitted into the electrode terminal hole135so as to couple the electrode terminal133to the circuit board140. The boss145may be fitted into the electrode terminal hole135so as to maintain the electrode terminal133in a temporarily coupled state prior to the final coupling.

The electrode terminal133may be stacked on the circuit board140while the boss145is fitted into the electrode terminal hole135. The electrode terminal133may be stacked on the bus bar150while the boss145is fitted into the electrode terminal hole135.

The electrode terminals133may be stacked in such a manner that one bent electrode terminal133ais disposed on the bus bar150and another bent electrode terminal133bis then stacked on the previous bent electrode terminal133aso as to form an area that overlaps the previous bent electrode terminal133a.

Referring toFIG. 4, the circuit board140may include a plate-shaped circuit board body141having a rectangular plate shape overall. The circuit board140may include the boss145protruding from one side thereof. The boss145may be configured to have a cylindrical shape, and may be easily fitted into and coupled to the electrode terminal hole135formed in the electrode terminal133.

The circuit board140may include the boss145perpendicularly protruding from the surface thereof that faces the cover clip160. The boss145may be fitted into the bus bar150, the electrode terminal133and the cover clip160, and may be coupled thereto.

The height of the boss145may be determined in consideration of the thicknesses of the bus bar150, the plurality of bent electrode terminals133aand133band the cover clip160into which the boss145is fitted. The height of the boss145may be set to be larger than the total height of the bus bar150, the plurality of bent electrode terminals133and the cover clip160, which are stacked on the circuit board140, so as to fully pass through the bus bar150, the plurality of bent electrode terminals133aand133band the cover clip, which are stacked.

The boss145may couple the bus bar150, the plurality of bent electrode terminals133and the cover clip160to the circuit board140, thereby preventing separation thereof after the coupling. The circuit board140may include a plurality of bosses145in order to increase the coupling force between the circuit board140and the bus bar150, the electrode terminals133and the cover clip160.

The plurality of bosses145may be arranged vertically, and may be coupled to the bus bar150, the electrode terminals133and the cover clip160in order to increase the coupling force between the circuit board140and the bus bar150, the electrode terminals133and the cover clip160. The plurality of bosses145may be arranged in an anteroposterior direction at predetermined intervals so as to be coupled to plurality of components.

The boss145may be fitted into the electrode terminal hole135formed in the electrode terminal133so as to couple the electrode terminal133to the circuit board140. The boss145may be fitted into the electrode terminal hole135so as to prevent separation of the electrode terminal133from the circuit board140. The electrode terminal133may be stacked on the circuit board140while the boss145is fitted into the electrode terminal hole135. The electrode terminal133may be stacked on the bus bar150disposed on the circuit board140while the boss145is fitted into the electrode terminal hole135.

The boss145may be fitted into the bus bar hole155formed in the bus bar150so as to couple the bus bar150to the circuit board140. The boss145may be fitted into the bus bar hole155so as to prevent separation of the bus bar150from the circuit board140. The bus bar150may be stacked on the circuit board140in the state in which the boss145is fitted into the bus bar hole155.

The boss145may be fitted into a coupling hole165(including165a,165bfor example) formed in the cover clip160so as to couple the cover clip160to the circuit board140. The boss145may be fitted into the coupling hole165so as to prevent separation of the cover clip160from the circuit board140. The cover clip160may be stacked on the circuit board140while the boss145is fitted into the coupling hole165. The cover clip160may be stacked on the bus bar150disposed on the circuit board140while the boss145is fitted into the coupling hole165. The cover clip160may be stacked on the electrode terminal133disposed on the circuit board140while the boss145is fitted in through the coupling hole165.

Referring toFIGS. 4 and 10, the circuit board140may include the electrode terminal passage hole142through which the electrode terminal133passes. The electrode terminal passage hole142may be formed to be vertically elongate. The electrode terminal passage hole142may be composed of a plurality of electrode terminal passage holes142corresponding in number to the number of plurality of electrode terminals133. The plurality of electrode terminal passage holes142may be arranged on the circuit board140in the anteroposterior direction.

The electrode terminal passage hole142may serve to dispose the electrode terminal133inserted there into to be spaced apart from the circuit board140such that the electrode terminal133easily passes through the circuit board140upon assembly.

The electrode terminal passage hole142may provide a space between the electrode terminal133and the circuit board140so as to prevent the electrode terminal133from being electrically connected to the circuit board140, thereby preventing unwanted energy loss.

Referring toFIG. 10, because it is difficult to accurately bend the electrode terminal133at an angle of 90 degrees owing to particular characteristics of the manufacturing process, size of the electrode terminal passage hole142may be determined such that the electrode terminal133is spaced apart from the circuit board140in consideration of bendability of the bent portion of the electrode terminal133.

The electrode terminals133may be arranged in the anteroposterior direction. The bent electrode terminals133may pass through the circuit board140and may be stacked one on each other between the circuit board140and the cover clip160.

The electrode terminal133may protrude through the electrode terminal passage hole142formed in the circuit board140. The bent electrode terminals133may be stacked on the bus bar150disposed on the circuit board140. The electrode terminals133may be stacked in such a manner that one bent electrode terminal133is disposed on the bus bar150and another bent electrode terminal133is then stacked on the previous bent electrode terminal133so as to form an area that overlaps the previous bent electrode terminal133.

One of the circuit board140and the cover clip160may include a coupling protrusion, and the other thereof may include a structure corresponding to the coupling protrusion. The coupling protrusion may be composed of snap protrusions163(including163a,163bfor example) and snap protrusions164(including164a,164bfor example). The structure corresponding to the coupling protrusion may be composed of snap holes or receptacles143(including143a,143bfor example) and snap holes or receptacles144(including144a,144bfor example), which are engaged with the snap protrusions163and164in a snap-fit manner.

In the embodiment, the circuit board140includes the snap protrusions163and164, whereas the cover clip160includes the snap holes143and144. Alternatively, it may be also possible to provide a configuration in which the cover clip160includes the snap protrusions163and164whereas the circuit board140includes the snap holes143and144.

Referring toFIG. 6, the snap holes143and144may be formed in a peripheral region of the bus bar150and the circuit board140. The snap holes143and144may be disposed to be coupled to the snap protrusions163and164. The snap holes143and144may include a plurality of snap holes143and144corresponding in number to the number of snap protrusions163and164.

The snap holes143and144may include an upper snap hole143disposed at an upper side of the bus bar150. The snap holes143and144may include a lower snap hole144disposed at a lower side of the bus bar150.

The snap holes143and144may be positioned such that the distance between the electrode terminal passage hole142and the peripheral edge of the circuit board140is greater than the distance between the snap holes143and144and the peripheral edge of the circuit board140, whereby the cover clip160covers the contact area between the plurality of electrode terminals133and establishes a snap-fit coupling.

In another embodiment of the present disclosure, the coupling protrusion may be composed of snap protrusions163and164. The structure corresponding to the coupling protrusion may be a snap groove, which is engaged with the snap protrusions163and164in a snap-fit manner. The snap groove may be formed in the peripheral region of one of the circuit board140and the cover clip160.

The snap groove may be positioned at the peripheral region of the circuit board140so as to be coupled to the snap protrusions of the cover clip160. The snap groove may guide the snap protrusions163and164to the coupling position of the circuit board140.

The snap groove may be formed at an upper side and/or a lower side of the circuit board140so as to be coupled to the snap protrusions163and164. Coupling between the snap groove and the snap protrusions163and164may provide an effect of facilitating attachment and detachment thereof, compared to coupling between the snap holes143and144and the snap protrusions163and164.

In the embodiment, the snap groove is formed in the circuit board140and the snap protrusions163and164are formed on the cover clip160. However, it is also possible to provide a configuration in which the snap protrusions163and164are formed on the circuit board140and the snap groove or snap holes are formed in the cover clip160so as to allow coupling there between.

In addition, it is also possible to provide a configuration in which the snap groove is formed in an upper portion of the circuit board140and the snap holes143and144are formed in a lower portion of the circuit board140such that they are coupled to the snap protrusions163and164of the cover clip160. Alternatively, it is also possible to provide a configuration in which the snap holes143and144are formed in an upper portion of the circuit board140and the snap groove is formed in a lower portion of the circuit board140such that they are coupled to the snap protrusions163and164of the cover clip160.

Referring toFIG. 7, the circuit board140may include a sub circuit board146, which serves to electrically connect a plurality of bus bar terminals156to each other so as to measure the voltage of each of the battery cells130. The sub circuit board146may be configured to have a rectangular plate shape overall.

The sub circuit board146may be disposed on the circuit board140so as to contact the bus bar terminals156. The sub circuit board146may extend in an anteroposterior direction so as to contact the plurality of bus bar terminals156.

A protrusion of the bus bar terminal156may be fitted into the sub circuit board146and coupled thereto. The sub circuit board146may be electrically connected to the bus bar terminal156so as to measure the voltage of each of the battery cells130. The sub circuit board146may transmit information about the measured voltage of the battery cell to a controller (not shown).

The circuit board140may include voltage terminals147through which voltage is input and output. The voltage terminals147may be provided at front and rear portions of an upper side of the circuit board140. The voltage terminals147may allow voltage to be output to the outside of the battery module100. Furthermore, the voltage terminals147may allow external voltage or charge external of the battery module100to be input to the battery module100.

Referring toFIG. 4, the bus bar150may include a bus bar body151having a rectangular plate shape overall. The bus bar body151may be configured to extend vertically.

The bus bar150may be disposed between a pair of electrode terminal passage holes142, which are arranged in the circuit board140in the anteroposterior direction. The bus bar150may be disposed between a pair of snap protrusions163and164, which are arranged vertically along the circuit board140.

The bus bar150may be coupled at one surface thereof to the circuit board140while being in contact with the circuit board140. The bus bar150may be coupled to the circuit board140by using, for example, heat fusion or other application of heat, such as at point158, for example.

The bus bar150may be disposed between the circuit board140and the cover clip160so as to contact the electrode terminal133. The bus bar150may contact the electrode terminal133so as to be electrically connected thereto.

Because it is difficult to accurately bend the electrode terminal133at an angle of 90 degrees owing to the particular characteristics of the manufacturing process, the bus bar150may be configured which may improve the state of contact between the bus bar150and the electrode terminal133in consideration of bendability of the bent portion of the electrode terminal133. The bus bar150may be rounded at the edge region thereof that is positioned to correspond to the bent portion of the electrode terminal133, which may improve the state of contact between the bus bar150and the bent electrode terminal133.

The plurality of bus bars150may be arranged in series in the direction in which the plurality of battery cells130are stacked on each other so as to be electrically connected to respective one of the battery cells130. The bus bar150may be coupled to the circuit board140in a contacting state. Each of the bus bars150may include the bus bar terminal156, which protrudes in one direction, and may contact the sub circuit board146so as to be electrically connected thereto.

The bus bar150may be provided with the bus bar hole155into which the boss145is fitted. The bus bar150may be provided in the center thereof with the bus bar hole155such that the boss145is fitted into and through the bus bar hole155and is coupled thereto. The bus bar150may include bus bar holes155in a number corresponding to the number of plurality of bosses145, which may increase the coupling force between the bus bar150and the circuit board140.

The boss145may be fitted into the bus bar hole155so as to couple the bus bar150to the circuit board140. The boss145may be fitted into the bus bar hole155so as to maintain the bus bar150and the circuit board140in a temporarily coupled state prior to the final coupling.

The electrode terminal may be stacked on the bus bar150while the boss145is fitted into the electrode terminal hole135. The bus bar150may be stacked on the circuit board140while the boss145is fitted into the bus bar hole155.

The bus bar150may include the bus bar terminal156, which protrudes in one direction so as to contact the sub circuit board146.

The bus bar terminal156comes into contact with the sub circuit board146such that the bus bar150is electrically connected to the sub circuit board146. The bus bar terminal156may be provided at the end thereof with a protrusion that is fitted into and coupled into the hole formed in the sub circuit board146such that the bus bar150is steadily and electrically connected to the sub circuit board146.

Referring toFIGS. 5, 7 and 8, the cover clip160may include a cover clip body161, which is configured to have a rectangular shape overall. The cover clip160may be made of an elastic material that is elastic in order to be detachably coupled to the circuit board140in a snap-fit manner.

One of the circuit board140and the cover clip160may include the coupling protrusion, and the other thereof may include a structure corresponding to the coupling protrusion. The coupling protrusion may be composed of the snap protrusions163and164. The structure corresponding to the coupling protrusion may be composed of the snap holes143and144that are engaged with the snap protrusions163and164in a snap-fit manner.

The cover clip160is configured to cover the contact area between the electrode133and the bus bar150, when viewed in one direction, so as to protect the electrode terminal133and the bus bar150from external shocks. The cover clip160may prevent foreign substances from entering the electrode terminal133and the bus bar150. The cover clip160may include the snap protrusions163and164, which are coupled to the snap holes143and144in a snap-fit manner.

In the embodiment, the cover clip160includes the snap protrusions163and164, and the circuit board140includes the snap holes143and144. Alternatively, it may be possible to provide a configuration in which the circuit board140includes the snap protrusions163and164and the cover clip160includes the snap holes143and144.

The snap protrusions163and164may be disposed so as to be coupled into the snap holes143and144. The snap protrusions163and164may protrude toward the circuit board140, and may include hooks formed at the end thereof so as to be coupled into the snap holes143and144.

The snap protrusions163and164may be detachably coupled into the snap holes143and144in a snap-fit manner such that each of the battery cells130is detachable from the battery module100.

A number of snap protrusions163and164corresponding to the number of snap holes143and144may be provided in order to increase the coupling force between the circuit board140and the cover clip160.

The snap protrusions163and164may include an upper snap protrusion163that is positioned at the upper end of the cover clip160. The snap protrusions163and164may include a lower snap protrusion164that is positioned at the lower end of the cover clip160.

Each of the snap protrusions163and164may be rounded at the portion thereof at which the snap protrusion meets the cover clip160, so as to prevent breakage of the bent portion attributable to concentration of stress.

The length of the snap protrusions163and164may be determined based on the total thickness of the elements stacked between the circuit board140and the cover clip160. The length of the snap protrusions163and164may be determined based on the thickness of the circuit board140into which the snap protrusions163and164are fitted.

Referring toFIG. 9, the snap protrusions163and164may have a length greater than the total thickness of the bus bar150and the plurality of bent electrode terminals133, which are stacked between the circuit board140and the cover clip160, plus the depth of the snap holes143and144. The cover clip160may be coupled to the circuit board140in a snap-fit manner so as to couple the bus bar150and the plurality of bent electrode terminals133to the circuit board140. The cover clip160, which is constructed as described above, may enable the circuit board140, the bus bar150and the plurality of bent electrode terminals133to be replaced with other ones.

Each of the snap protrusions163and164may be provided at the end thereof with the hook, with a surface of the hook that is in contact with the circuit board140being inclined toward the snap hole. Insertion of the cover clip160into the circuit board140may be guided by the inclined surface of the hook, and it may be possible to increase the force with which the plurality of electrode terminals133is coupled to the circuit board140by the cover clip160.

In another embodiment of the present disclosure, the structure corresponding to the coupling protrusion may be a snap groove, which is engaged with the snap protrusions163and164in a snap-fit manner. The snap groove may be formed in a peripheral region of one of the circuit board140and the cover clip160.

The snap protrusions163and164may be configured so as to be coupled to the snap groove formed in a peripheral region of the circuit board140. The snap groove may guide the coupling of the snap protrusions163and164to the circuit board140.

The snap protrusions163and164may be coupled to the snap groove formed in an upper side and a lower side of the circuit board140. The snap protrusions163and164may be more easily coupled to and removed from the corresponding structure in the combination of the snap protrusions163and164and the snap groove than in the combination of the snap protrusions163and164and the snap holes143and144.

In the embodiment, the cover clip160includes the snap protrusions163and164, and the circuit board140includes the snap groove. Alternatively, it may be possible to provide a configuration in which the circuit board130includes the snap protrusions163and164and the cover clip160includes the snap groove.

The cover clip160may include the coupling hole165, into which the boss145is fitted. The coupling hole165may be formed in the center of the cover clip160so as to be engaged with the boss145.

The coupling holes165may include a number of coupling holes165in number corresponding to the number of plurality of bosses145in order to increase the coupling force between the circuit board140and the cover clip160.

The coupling hole165may be configured to have a shape corresponding to the shape of the boss145such that the boss145is fitted into the coupling hole165. The coupling hole165may be formed to have a circular cross-section so as to correspond to the circular cross-section of the boss145.

The circuit board140and the cover clip160may be configured such that the coupling protrusion and the portion corresponding to the coupling protrusion are coupled to each other by heat fusion in order to stably couple the cover clip160to the circuit board140. The circuit board140and the cover clip160, which are coupled to each other by heat fusion, may be separated from each other by the application of heat.

Referring toFIG. 8, when the cover clip160comes into contact with the electrode terminal133, a loose connection may occur due to the rounded portions formed at the connecting regions between the snap protrusions163and164and the cover clip body161. The cover clip160may include a cover clip contact surface162that protrudes from the center of the surface of the cover clip160facing the circuit board140in order to bring the cover clip160into stable contact with the electrode terminal.

The cover clip160may include a buffer portion or cushion168on the surface facing the circuit board140in order to improve the electrical connection of the plurality of electrode terminals disposed between the cover clip160and the circuit board140.

The buffer portion168may be made of a material having a certain amount of elasticity. The buffer portion168may be a rubber packing.

The buffer portion168may be disposed between the peripheral region of the cover clip contact surface162and the peripheral region of the cover clip body161. The buffer portion168may be configured so as to protrude further than the cover clip contact surface162when the cover clip160is separated from the circuit board140.

The battery module100, which is constructed as described above, is constructed such that the plurality of electrode terminals133of the battery cells130are detachably coupled to each other. Accordingly, when one of the plurality of battery cells130in the battery module100develops a problem, the arrangement of the disclosure provides for being able to separate only the problematic battery cell for replacement.

The battery module100provides a mechanical coupling structure designed to electrically connect the plurality of electrode terminals133to each other by using, for example, snap-fit coupling between the circuit board140and the cover clip160. Although a conventional coupling structure may provide a problem in which a weld becomes deteriorated due to wear of a welding tool over time, the mechanical coupling structure of the disclosure provides an effect of being able to stably maintain coupling quality for a long period of time.

The battery module according to the embodiment provides an effect of being able to uniformly couple the plurality of electrode terminals133to each other, contrary to a conventional coupling structure, in which a welding connection state varies depending on the duration of use, welding point, conditions and the like.

In the conventional art, there is a risk of the interior of a battery cell being damaged by heat generated during welding of a battery module, and the battery module is adversely affected by the heat. The battery module100according to the embodiment, which is a mechanical coupling structure employing the cover clip160, provides an effect of obviating concern about damage to the battery module100attributable to heat.

A battery module200according to another embodiment of the present disclosure will be described with reference toFIG. 11with a focus on structures different from those of the first embodiment, and a description of structures identical to those of the first embodiment may be omitted.

A circuit board240according to the embodiment may include a boss245(including245a,245bfor example), which is formed on the surface thereof facing the cover clip260so as to protrude perpendicular relative to the surface of the circuit board240.

The boss245may be provided at the end thereof with a snap portion for coupling into a coupling hole265, in the cover clip260, in a snap-fit manner. The snap portion may be formed by dividing the end of the boss245. Specifically, the snap portion may be formed by dividing the end of the boss245in a crisscross shape.

The snap portion may be coupled to a cover clip260in a snap-fit manner after being fitted into the cover clip260. Since the snap portion provides additional coupling force between the circuit board and the cover clip260in addition to the coupling force from the snap-fit coupling between snap protrusions263(including263a,263bfor example) and snap holes243(including243a,243bfor example) and lower snap protrusions and snap holes, it may be possible to increase the coupling force between the circuit board240and the cover clip260.

The snap portion may be fitted into the coupling hole265in the cover clip260, and then coupled to the cover clip260by using, for example, heat fusion. It may be possible to stably couple the cover clip260to the circuit board240. The circuit board240and the cover clip260, which are coupled to each other by using, for example, heat fusion, may be separated from each other by the application of heat.

A coupling hole in an electrode terminal233may be sized such that the boss245including the snap portion is fitted into the hole. A coupling hole in a bus bar250may be sized such that the boss245including the snap portion is fitted into the hole. A coupling hole265in the cover clip260may be sized such that the boss245including the snap portion is fitted into the hole.

FIG. 11also shows circuit board body241, electrode terminal passage hole242a, sub circuit board246, bus bar terminal256, and cover clip body261.

Hereinafter, a battery module300according to a further embodiment of the present disclosure will be described with reference toFIG. 12with a focus on structures different from those of the battery module100according to the first embodiment, and a description of structures identical to those of the battery module100of the first embodiment may be omitted.

A bus bar150according to the embodiment may be provided a surface thereof facing a cover clip360with a plurality of protrusions, in order to improve the electrical connectivity of a plurality of bent electrode terminals133disposed between the bus bar150and the cover clip360.

The plurality of protrusions, which are formed on the surface of the bus bar150facing the cover clip360, may be arranged in a matrix pattern. The plurality of protrusions may be arranged so as to alternate with a plurality of protrusions formed on the cover clip360in order to improve the electrical connectivity of a plurality of bent electrode terminals133disposed between the bus bar150and the cover clip360.

The cover clip360according to the embodiment may include an electric conductor366on the surface thereof that faces a circuit board140so as to improve the electric connectivity of the plurality of electrode terminals133. The cover clip360may be provided, in the surface thereof that faces the circuit board140, with a recess for receiving the electric conductor366therein, and the electric conductor366may be partially fitted into the recess.

The cover clip360may include a coupling hole365(including365a,365bfor example) into which a boss145is fitted. The cover clip360may have formed therein the coupling hole365, which allows the boss145to be fitted into the cover clip body361and the electric conductor366.

The cover clip360may include an uneven portion on the surface thereof that faces the circuit board140. The cover clip360may include the uneven portion composed of a plurality of protrusions, which protrude a predetermined height and are arranged in a matrix pattern.

The cover clip360may include the plurality of protrusions provided on the electric conductor366so as to improve the electrical connectivity of the plurality of bent electrode terminals133disposed between the bus bar150and the cover clip360. The cover clip360may include the plurality of protrusions provided on the surface of the electrical conductor366that faces the circuit board140, the plurality of protrusions being arranged in a matrix pattern.

The plurality of protrusions may be alternately arranged with the plurality of protrusions formed on the bus bar150so as to improve the electrical connectivity of the plurality of bent electrode terminals133disposed between the bus bar150and the cover clip360.

Although the cover clip360according to the embodiment includes the plurality of protrusions provided on the electrical conductor366, the plurality of protrusions may alternatively be provided on the surface of the cover clip body361that faces the circuit board340, without the electrical conductor366. As shown inFIG. 12, the cover clip360may include snap protrusions363a,363b,364a,364b.

A battery module400according to a further embodiment of the present disclosure will be described with reference toFIGS. 13 to 16with a focus on structures different from those of the battery module100according to the first embodiment, and a description of structures identical to those of the battery module100of the first embodiment may be omitted.

A bus bar450according to the embodiment may include a linear protrusion457(including457a,457bfor example) that corresponds to a linear groove467(including467a,467bfor example) in a cover clip460which may improve the electrical connectivity of a plurality of bent electrode terminals433(including433a,433bfor example) disposed between the bus bar450and the cover clip460.

The linear protrusion457may be positioned at the center of the bus bar450and may extend in the longitudinal direction of the bus bar450. The linear protrusion457may extend vertically.

The linear protrusion457may extend to the lower end of the bus bar450from the upper end of the bus bar450. The linear protrusion457may be composed of a pair of linear protrusions457aand457b, which are disposed parallel to each other.

The linear protrusion457may be positioned so as to be vertically aligned with the point at which the cover clip460and the circuit board440are coupled to each other in a snap-fit manner when the bus bar450is disposed on the circuit board440, thereby allowing the pressure resulting from snap-fit coupling to be efficiently transmitted to the electrode terminals433contacting the linear protrusion457.

The linear protrusion457may protrude by a height corresponding to the depth to which the linear groove467is formed in the cover clip460. The linear protrusion457may be connected to the surface of the bus bar450so as to improve the contact efficiency with the plurality of electrode terminals433.

Although the linear protrusion457is illustrated as being configured to have a triangular cross-section in the embodiment, the linear protrusion457may be configured to have some other cross-section shape.

In the embodiment, the cover clip460may include an uneven portion provided on the surface thereof that faces the circuit board440so as to improve the electrical connectivity of the plurality of electrode terminals433. The uneven portion may be embodied as the linear groove467, which extends in the longitudinal direction of the cover clip460.

The linear groove467may be positioned at the center of the cover clip460and may extend in the longitudinal direction of the cover clip460. The linear groove467may extend vertically.

The linear groove467may extend to the lower end of the cover clip460from the upper end of the cover clip460. The linear groove467may be composed of a pair of linear grooves467aand467b, which are disposed parallel to each other in a horizontal direction.

The linear grooves467aand467bmay be aligned with the snap protrusions463(including463a,464b) and snap protrusions464(including464a,464b) in a vertical direction so as to efficiently transmit pressure resulting from the snap-fit coupling to the electrode terminals433contacting the linear grooves.

The linear groove467may be depressed by a depth corresponding to the height of the linear protrusion467formed on the bus bar450. The linear groove467may be connected to the surface of the cover clip460and may correspond to the linear protrusion457which may improve the contact efficiency with the plurality of electrode terminals433.

Although the linear groove467is illustrated as being configured to have a triangular cross-section in the embodiment, the linear groove467may be configured to have some other cross-sectional shape.

FIGS. 13-16further show circuit board body441; electrode terminal passage holes442a,442b; snap holes443a,443b; bosses445a,445b; sub circuit board446; voltage terminals447; bus bar body451; circuit board/bus bar attachment458; bus bar holes455a,455b; bus bar terminal456; cover clip body461; cover clip contact surface462; coupling holes465a,465b(of the cover clip460); and buffer portion468.

Hereinafter, a battery module500according to still a further embodiment of the present disclosure will be described with reference toFIGS. 17 and 18with a focus on structures different from those of the battery module100according to the first embodiment, and a description of structures identical to those of the battery module100of the first embodiment may be omitted.

A cover clip560according to the embodiment may include an electric conductor566provided on the surface thereof that faces a circuit board540so as to improve electrical connectivity with a plurality of electrode terminals533(including533a,533bfor example). The cover clip560may be provided, in the surface thereof that faces the circuit board540, with a recess for receiving the electrical conductor566, and the electrical conductor566may be fitted partway into the recess.

The cover clip560may include a coupling hole565(including565a,565bfor example) into which a boss545bis fitted. The coupling hole565may be formed so as to allow the boss545bto be fitted into the cover clip body561and the electrical conductor566.

The cover clip560may include an uneven portion on the surface thereof that faces the circuit board540, so as to improve electrical connectivity with a plurality of electrode terminals533. The uneven portion may be embodied as a linear groove567(including567a,567bfor example), which extends in the longitudinal direction of the cover clip560.

The linear groove567may extend to the lower end from the upper end of the electrical conductor566disposed on the surface of the cover clip560that faces the circuit board540. The linear groove567may be composed of a pair of linear grooves567a,567b, which are formed in the electrical conductor so as to be parallel to each other in a horizontal direction. The linear groove567may be formed in the electrical conductor566so as to improve the electrical connectivity of the plurality of electrode terminals533.

A bus bar550according to the embodiment may include a linear protrusion557(including557a,557bfor example) that corresponds to the pair of linear grooves567in a cover clip560so as to improve the electrical connectivity of a plurality of bent electrode terminals533disposed between the bus bar550and the cover clip560.

The cover clip560may include a buffer portion or cushion568provided on the surface thereof that faces the circuit board540so as to improve the electrical connectivity of the plurality of electrode terminals disposed between the cover clip and the circuit board.

The buffer portion568may be made of a material having a predetermined elasticity. The buffer portion568may be a rubber packing.

The buffer portion568may be disposed between the peripheral region of the electrical conductor566and the peripheral region of the cover clip body561. The buffer portion568may be configured so as to protrude further than the electrical conductor566when the cover clip560is separated from the circuit board540.

Hereinafter, a battery module600according to yet a further embodiment of the present disclosure will be described with reference toFIG. 19with a focus on structures different from those of the battery module100according to the first embodiment, and a description of structures identical to those of the battery module100of the first embodiment may be omitted.

A cover clip660according to the embodiment may include a plurality of covers, which bring bent electrode terminals133into contact with a bus bar150. The cover clip660may cover a plurality of units, each of which is composed of the electrode terminal133and the bus bar150, which are stacked. The cover clip660may be configured to have a plurality of cover clips660according to the first embodiment, which are connected to each other.

Since the cover clip660, which is constructed as described above may simultaneously cover a plurality of units, each of which is comprised of the electrode terminal133and the bus bar150that are stacked, it may be possible to facilitate coupling between the cover clip660and the circuit board140.

In addition, since the cover clip660is configured to have a plurality of covers, which are connected to each other, the manufacture thereof may be facilitated. Furthermore, since the plurality of covers of the cover clip660are connected to each other and combine their coupling force, it may be possible to increase the coupling force between the cover clip and the circuit board140.

Since the battery module according to the present disclosure includes the cover clip, which is coupled to the circuit board so as to cause the bent electrode terminals to contact the bus bar, and the circuit board and the cover clip are detachably coupled thereto, there may be an advantage of allowing the plurality of battery cells to be detachably coupled thereto.

Since the battery module is configured such that one of the circuit board and the cover clip includes the snap protrusion and the other thereof includes the snap hole, it may be possible to detachably couple the plurality of bent electrode terminals and the bus bar.

When one of the plurality of battery cells constituting the battery module develops a problem, the cover clip is separated from the circuit board, and electrode terminals connected to each other are separated from each other, thereby allowing the problematic battery cell to be removed from the battery module.

The battery module according to the present disclosure, which includes the circuit board and the cover clip, which are coupled thereto, and which electrically connects the plurality of electrode terminals to each other, may provide advantages in that there is no problem in which welding quality is deteriorated due to wear of welding tools over time in a conventional process of manufacturing a battery module and in that it is possible to uniformly couple the electrode terminals to each other.

The battery module according to the present disclosure, in which the circuit board, the electrode terminals, the bus bar and the cover clip are mechanically coupled to each other, confers an advantage in that there is no concern about damage to the battery cell attributable to generation of high-temperature heat, unlike a conventional welding process.

The battery module according to the present disclosure, which includes the linear groove longitudinally formed in the surface of the cover clip that faces the circuit board, and the linear protrusion formed on the bus bar so as to correspond to the linear groove, confers an advantage in that it may be possible to improve electrical connectivity between the electrode terminals of the plurality of battery cells.

The present disclosure provides a battery module in which battery cells are individually coupled to the battery module in a detachable manner. Further, a problem in which welding quality is deteriorated due to wear of welding tools over time in a process of manufacturing a battery module may be solved.

A problem in which a battery cell is damaged due to heat generated during welding of a battery module may be solved based on the present disclosure.

The electrical connectivity of a battery cell may be improved based on the present disclosure.

In accordance with an aspect of the present disclosure, the above and other objects can be accomplished by the provision of a battery module including a plurality of battery cells, which are stacked on each other and each of which includes electrode terminals which protrude at one side of the plurality of battery cells and are bent, at least one bus bar each of which is configured to electrically connect the electrode terminals of adjacent battery cells among the plurality of battery cells to each other, a circuit board disposed at the one side of the plurality of battery cells and including voltage terminals through which voltage is input and output, and at least one cover clip coupled to the circuit board so as to bring the bent electrode terminals into contact with the at least one bus bar.

One of the circuit board and each of the cover clips may include a snap protrusion, and the other of the circuit board and each of the cover clips may include a snap hole, which is coupled to the snap protrusion in a snap-fit manner.

The bent electrode terminals of the plurality of battery cells may pass through the circuit board and be stacked on each other between the circuit board and each of the cover clips. Each of the bus bars may be disposed between the circuit board and a corresponding one of the cover clips. The circuit board may include electrode terminal passage holes through which the electrode terminals pass.

The circuit board may include a snap hole formed between each of the bus bars and a peripheral edge of the circuit board. Each of the cover clips may cover a contact portion between a corresponding one of the electrode terminals and a corresponding one of the bus bars when viewed in one direction and may include a snap protrusion coupled to the snap hole in a snap-fit manner.

Each of the cover clips may include a linear groove formed in a surface that faces the circuit board, the linear groove extending in a longitudinal direction of the cover clip.

Each of the bus bars may include a linear protrusion that is formed to correspond to the linear groove.

A battery module comprising a first cell having a first electrode terminal, a second cell having a second electrode terminal, and the first electrode terminal and the second electrode terminal forming an electrode terminal set; at least one bus bar having a bus bar contact surface, a support provided on one side of the first and second cells, and at least one cover clip that engages into the support to sandwich the electrode terminal set and the bus bar contact surface to prevent separation of contact between at least one of (a) the first and second electrode terminals or (b) the bus bar contact surface and the electrode terminal set.

It will be understood that when an element or layer is referred to as being “on” another element or layer, the element or layer can be directly on another element or layer or intervening elements or layers. In contrast, when an element is referred to as being “directly on” another element or layer, there are no intervening elements or layers present. As used herein, the term “and/or” includes any and all combinations of at least one of the associated listed items.